About the loose handle, I know you said you had tried washers, but what type of washers?
Every one of my planes had loose totes, the best way I found was to use a spring washer that fits into the gap; never needed more than one, that way you tighten down and it will be exactly the right height, the theory is even with seasonal movement of the handle it will stay tight. So far all with spring washers are not moving, cracking or any other problems