If it's in warranty and its actually not correct the way it's suppose to be, I think HL will take care of it.
They offered to replace the cushions with new ones exactly the same as the ones the unit came with. I told him that wont work because he would have to replace them after every few camping trips. And to make it even more aggravating, I would have to haul it to another town so the dealer could sign something, some papers each time. We didn't buy it brand new to sit in the dealer's lot waiting for someone to look at the cushions when they had the time and sign paper work. Apparently you can't just take the cushions in.... and why bother when the new ones would flatten and the cheap covers crinkle and wrinkle in no time.
But if you knew this unit had issues,
If we knew this brand brand new unit had issues, it would have stayed on the lot in Elkhart. And the design flaws do not become apparent until you go camping with it for a week or two or take a trip. No dealer will allow that before you buy the RV.
.... and if you did a good PDI you would have found it un level I would think,
You think wrong. How many people would think to bring a handful of levels to make sure the cabinets and dining set are level when the floor is level? Did you? How did you check for design flaws there on the lot?
.....then why did you sign for it?
What makes you think the dealer who got it from HL or that HL itself told us about all the design flaws and that the cabinets tilted to streetside? That the cushions were just for looks? That no one checked the outside shower for kinks? That you couldn't really use the unit where the ground was not level as a pancake or the spare tire would drag and the rear stabilizers would get bent or ripped off - which is what happened the first or second time out with it. BTW, I called HL about the stabilizers dragging on every incline and that they were finally destroyed. That design flaw was not considered, we had to pay to replace them and we can't use them bolted to the frame or they too will be destroyed. We bought better ones and keep them in the cubby until parked. They didn't tell us before we signed that this TT needs super heavy duty dolly wheels attached to the rear frame to keep the slide-out try from being ripped off on any small incline. BTW, the rear tray still drags, even with the dolly wheels and I know one day we'll destroy the tray by simply going to a gas station or up an incline in one of the CG here in TN. Would we have bought this TT knowing all these things? Not on your life. No one would have and that includes YOU.
It seems you have been mostly un happy with it from the start if I remember right.
See above, we were quite happy until all the design flaws and problems started to become known. That includes having to buy a FantasticFan so we can get air to breath when it storms or rains plus two Maxxaire vertical louver vents for both slider windows. HL would not add the better crank windows even though we offered to pay for them, and pay for them to be installed as our TT was being made. This 28BRS has very poor ventilation in bad weather due to the sliders and awning-windows that have no adjustments. These are design flaws not known until you spend time in the unit. Flaws the other two RVs we had did not have.
Don't take this wrong but it is the reason I took a 9 page checklist, that had me down on the floor checking for scuff marks and holes. Too bad we have to do this, but you do get what you pay for. And I wanted the most for my money.
You can be sure we will never again buy another poorly designed unit like this one. The floor plan and layout are great, don't get me wrong. It was the floor plan we were looking for. They got that right, but in all other areas,.... this RV is sorely lacking, a real disappointment.
We expected a glitch or a problem here and there but we were overwhelmed with one thing after the other, starting with the 2 rear jacks being so close to the ground they were destroyed before the 1st month was up, plus a front one bent. 
