...The only somewhat helpfull option seems to build a holder that prevents users from rotating the mirror after construction is finsihed.
I believe that was the intent with the 3-lobed secondary mirror support (post #14). The 3 tilt adjustment screws are pretty much confined to a fixed rotation.
...But this adds problem to the initial construction, as these missing degrees of freedom would then require more expensive or heavy adjustment elsewhere to get it initially set up.
And that problem has already happened, with the simplest solution being to re-enable rotation.
...after "normal' collimation (you) end up with a notably tilted secondary, just reset the secondary tilt so the gap in between the spider and the secondary holder is essentially even...
That's a good idea, but it presumes the other geometries (focuser, spider, truss framework, etc.) are not contributing to the observed error. This was pretty common with truss work Dobs (Starmasters in particular) with thin focuser boards that would warp under the truss stresses, ultimately tilting the focuser. I fixed quite a few of those over the years...
...Any alignment issues with these are adressed at contruction time - its not things that get out of whack due to normal use.
I agree, until it's something that wasn't addressed at construction time (like the 3-lobe secondary mirror mount) or it happened due to normal use (like the StarMaster UTA). Another one that has apparently slipped by the construction gurus is a secondary mirror that's glued to its mount with the major axis misaligned to the mounting's major axis. I've only seen a few of those (but I can only assume there are more out there that haven't been fixed, quietly (or maybe not-so quietly) contributing to secondary mirror "drama").
...So anytime your collimation angst drives you into modifying the secondary holder, its a lot more likely that you are going to permanently and possibly fatally damage an otherwise not broken at all scope.
The modifications I suggest are usually simple: stainless steel fender washers to enable rotation, or a focuser mounting plate with push-pull focuser leveling screws, nothing that would "fatally" damage an otherwise skewed secondary mirror. (Fixing an improperly glued secondary mirror is a different problem, and the solution is not for the faint of heart. If the problem is discovered in the manufacturer's warranty period, a new replacement part is the "easy" solution.)
...Its similar with the degrees of freedom to adjust the secondary. Even if the rotation axis for the secondary were different, you would be able to destroy alignment as easily as with the normal configuration. So it really would not help.
I'm not sure I understand what you're saying here. If the secondary does not have rotation enabled (the 3-lobe secondary mirror mounting), and the secondary mirror placement (and other geometries) is correct, any subsequent secondary mirror error is then confined to tilt and/or offset, which should be much easier to resolve, especially for beginners. I understand what the manufacturer is trying to do, and, thankfully, they haven't created an unresolvable problem.
...But this adds problem to the initial construction, as these missing degrees of freedom would then require more expensive or heavy adjustment elsewhere to get it initially set up.
Considering the number of scopes I've seen with the spider vanes mounted incorrectly (preventing optimal secondary mirror offset) and others with the spider hub rotated incorrectly (no tilt adjustment screw aligned with the focuser axis) complicating simple tilt adjustments, it's not always initial construction... Assembly complications require an additional level of collimation sleuthing.
You brought up a lot of interesting points! 
Edited by Vic Menard, 27 March 2025 - 07:24 PM.