Kevin - the more I read the more confused I get.
1. What is the normal course for a "lemon law" type issue in Canada?
2. Has your dealer brought DC's Zone representative in to help you? In the US, a dealer can be instrumental in getting resolution to a customer dispute if they agree that the customer has a problem that they (the dealer) cannot solve. (The only thing you've said about your dealer is that they said your frame looks like all the other Vipers they have seen.) They bring in a Zone person and sometimes ZONE mechanics, etc. to determine the casue. If they can't fix, then they try to work with you toward an amicable agreement.
3. Has this been going on for the entire three years you have had this car? If so, my guess is that any legal recourse like lemon law will be expired. it's 18 months that I am familiar with here. If not, when did it start?
4. Do you have binding arbitration set up in Canada like they do in the US? Most major car companies will allow and independent 3rd party to assist in dispute resolution (as part of lemon law) and abide by thier decision. If it looks like it's not going to go their way, they usually offer to settle beforehand as it avoids a true "lemon law" ding.
5. How many days has your car been out of service due to this issue? Usually there is a 28/30 day requirement for lemon law OR a X times try to fix for the same problem. you don't really say how many times you've had the car inspected, repairs attempted, etc.
6. Has your dealer told you what is wrong - or have they just thrown up their hands and said "we don't know?" It seems to be that you have a symptom of a problem, but no determination of the cause. Until a cause can be found, it's the dealer's issue to either find it or give up. If they give up, then it'd be DC's issue, as their service outlets could not properly carry out their warranty.
Maybe it's just your writing style, but I don't see very many FACTS, but more I see your thoughts, assumptions, allegations, and disappointment.
When I went through a lemon law issue, it's important to clearly spell out things with dates you brought the car in for service, where it went for service, how many times it was in for the same problem, what was written on the repair order as far as the problem/complaint and if the dealer found anything. I can't see where you've said what (if anything) the dealer did or tried to do to fix your car's problem. if they haven't done anything, then another dealer might be in order, as well as a call to DC-Canada or look in the back of your warranty book and see what options are available to you (if that applies in CA)
Sorry for my ignorance in Canadian legal issues - but I have to think there is something similar to lemon law available to you.
And no, I am not trying to sell you anything, just trying to logially go through your complaint and share what I have seen in the past 7 years. My mentioning the track stuff was not to say DC should cover race vehicles, but to point out that MANY viper owners subject their cars to the rigors of track driving and SOME race their cars - of these cars, I have not seen issues such as you are stating that you have - and that harder use of track driving should have brought this weakness to the forefront MUCH faster than any daily driver use.
Your disappointment is evident. And I am sure that whomever inspected your car on the lift knew how unhappy you were and reinforced your disappointment by saying "you paid how much?", but that doesn't mean the car is substandard or that the person saying that knows what the car SHOULD look like. Nor does your loss of confidence take the place of an identified defect when asking for compensation from the manufacturer (unless of course, both your dealer and DC threw up their hands and said "we can't fix")
I am sorry you have had such a bad experience and wish you the best in getting it resolved.