Fine points there Sam. I wouldn't necessarily term the unfinished edges as grossly burred, but would agree they're very sharp due to a lack of treatment for same or lack of chamfering. When inserting a finger into any cutout and drawing it outward over the edge you can feel a slight raising, or very small continuous burr. This is an unforgiving razor-like edge and it's punishing anything that comes into contact with it. Even without a burr a perfect undressed 90° cut will be a knife of sorts. As the design, materials and overall manufacture seem to be excellent, I'd have to term it a defect rather than a design flaw. Their "A" branding cutout is also quite prominent in terms of it's abrading qualities. I concur with what AltRider said about these units unfortunately having missed a finishing step. Hopefully the fallout from this problem won't bite them too badly.
To your point of riding posture I think you're right on as I keep my feet in tight while standing.
If you need another .02 regarding KLIM gear... They're the most durable, comfortable, waterproof, efficient, and intelligently featured apparel I've used. In fact, this year I've switched my entire layering system to KLIM, right down to socks, skivvies, and mid-layers.
In all the years I've been riding I don't believe I've ever bought an AltRider product but have always had a good perception of them through others experience and hearsay. That perception was reaffirmed a short while ago when I received their latest reply expressing concern for my gear. They've asked for pictures of the damage which I'll furnish tomorrow. They should be pleasantly surprised that I won't be pursuing the damages on the pants as I've unfortunately been responsible for worse damage since. Sure, I could just send pics of the damage their product caused, but thankfully I'm not wired so poorly. On that, as great as KLIM gear is, it's no match for carelessly discarded serpentine. An expensive finding.
Seems me and sharp things aren't getting along too well lately.
Good for you having them in town. Convenient in any event.