Thanks guys.

I am "mismatching" the rotors with the calipers because my hubs are Shimano centerlock. So, I don't have the problems with correct tightening pattern.

When I thought it might be a contaminant, I was willing to work with this. Given that the rotor is brand new, and from Nashbar, I'm just going to order another, then return this one. Maybe I'm being wasteful, but while I'm willing to do some work on a used rotor, I've NEVER had one right out of the package need attention on the order of, say, dremel tools.

The calipers were working perfectly with my "Deore" level rotors, so I'm just going to put one of the old ones back on. Replacement for this one already ordered.

I love to tinker and repair, but I have little patience for "out of the box" failures. You guys have persuaded me that this is very likely a shape/structure flaw in the rotor itself.