In the case of the seat stay, the stress relief hole at the bottom of the seat lug slot was far too close to the edge of the seat stay. In the case of the head tube, the top and down tubes were clocked, so the miter didn't close. It certainly didn't help that the lug had been thinned so much

I could have fixed the seat stay issue by replacing the stays. Too much work, but that's the way I would quote it in the future and let the customer decide. In the case of the head tube, it's really a gonner.