You reply back to this guy and tell him that it was the faulty seams that caused this to break, not an act of god. If that is still there stance on the matter, inform them that you will be contacting your lawyer, the BBB, and the Attorny general of Wisconsin, since they have a 3 yr warranty (read the warranty, make sure it doesnt say "except for acts of god") and are not standing behind it. That should get things rolling in your favor. Sorry for the crappy product though.
Bummer dood I do hate bedcovers but the one I had was Extang and I have to admit it was a tough booger.....
I'm actually pretty angry right now just reading through this!!!!! I'd stand my ground and follow Vanofords advice tell em the stitching is the problem and is part of the manufacturing process, not the wind! then WHEN you get your new cover sell it on Craigs to pocket some $$ for a nicer setup! Also let us know what mark says so we can all email BCA with "Attention Mark Foehring" and write, you are a douche and don't stand behind your warranties and will not see any business from a large Ford Forum community...