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This is how I've gotten all of my pieces and have been happy. I would have no problems calling the Dawsonville Outlet in GA and asking for Michael to ship me a piece. He was very good at going in the back and finding one with only a pin dot of miscolor.
However, I personally, would not have the same comfort level with the Orlando, FL outlet store. I went there in person and had to keep asking for a different box to look at and finally found one I was happy with that didn't have pitting on the interior floor of the 5qt oval pot.
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I have several le creuset, all seconds. Don't even know what the 'flaw' is in most of them; the last one I bought was a dutch oven where the first one I picked out had a flaw that I hadn't seen, and the sales woman picked out another one for me, which had a much smaller flaw (a minor drip, absolutely no effect on the cooking abilities). They're a really good deal.
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re: Bat Guano
I've bought a number of seconds at a LeCreuset outlet store (this one happens to be in Woodbury Commons, in Harriman, NY. You have to look carefully to even find the flaw, but I've gone through a number of similar pieces to find the best (often with the help of one of their salespersons). If you sign up with an outlet store, they'll send you discount cards on occasion which can make the deal even better.
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I also have several second pieces I picked up at the outlets. My experience was the same as everyone else here...cosmetic flaws only and not at all affecting performance.
I sell LC but I myself wouldn't pay full retail for it when there is the option of the seconds from the outlets...especially when there's a good sale going(like the postcard I just got for 30% off the outlet's price on both first and second quality!).
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The blemishes are 99% cosmetic and in the colored enamel (not the cooking surface). Even though LC has a seconds "program" they really do destroy any piece that doesn't meet exacting standards and if some piece is horrible once you bring it home the lifetime guarantee applies. If you're going to an outlet location though be aware that they also sell firsts as well at deeply discounted prices. And they also do set discounts counting lids as a piece (and you can mix firsts and seconds). I have a few "full price" pieces but nearly all of my extensive collection comes from the outlet.
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re: redgypsy
I just purchased a Le Creuset second from Home Goods and looked up "seconds" to see what it's about. After reading this thread, I went to examine my dutch oven. It has some light scratches on the bottom (the surface that touches the heat) -- is that something I should be worried about? And what is the 'worse case scenario' -- I mean, what does it affect?
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I've owned many second quality pieces for more than ten years. Choose carefully, look at each piece. All the flaws in mine are cosmetic - a small drip, etc. They have never affected cooking capabilities and the only way I know which is 1st quality and which is 2nd is by size; i.e. the very large pieces I would never have bought at full price are all seconds.
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