Since you are pretty sure the steel came from the same strip as some of the other blades that HT'd properly, I'd expect the problem to be an error in Rc testing. Just a VERY slight warp that might not be noticed and placed at test point could surely throw the test off a tad. Any idea how many places your HT'er tested the low Rc blade? The HT'er contacting you about the low Rc value before shipping back to you for discussion is a VERY good point in his favor for sure.
Nick, what part of the world are you in? If here in USA I'd be happy to retest those blades if you wish. Just two blades could be shipped 1st class for around $5 (each way) for 16 oz or less in a package/envelope. I doubt it's worth the $10 total shipping for testing, and if you're not in USA that's totally out of question. (one of the good reasons to have profile filled out).
Ken H>