Sigma 120-300mm f/2.8 EX APO DG HSM woes

I strongly suggest you try some focus micro-adjustment before sending it back. It is quite fast to do and can yield surprisingly excellent results when, as in your case, it looks like the camera is slightly mis-focusing.

Plus I'd be going for 1/500th and faster for that sort of action to try and freeze it. 1/1000th is usually where I try and get to.
 
if you send it back,

at work we use fastlane. they themselves use DHl but are significantly cheaper (how does that work then) and offer full insurance
 
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