Well, it was the pedal--for the 2nd time!
For some reason, the wrong resistor was used for the lead channel circuit and that was what was causing the problem.
I didn't feel like waiting for yet another pedal to be sent, so I went to Radio Shack got the right part and fixed it myself.
I'm sure stuff like this happens to pedal makers some times, but in both instances the guy was like "well, none of my other pedals have this problem, or I haven't seen this before...and i've sold tons of these..."
I felt like I had to "prove" that it was the pedal and not my system that was problem, including taking it apart and ohming the resistors, etc.
After that it it was "Oh, my mistake..."
I'm happy that it's working now, but I don't exactly feel "great" about the whole transaction and I definitely would think twice about buying again or recommending them.
It seems to me, if you are charging a premium price for a relatively simple pedal--make sure it works!!
Rant over. :wink: