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This is what I told you on Twitter :)
Your contract is with the retailer who sold you the faulty goods, not the manufacturer. So the retailer should sort it out.
And the answer to your postage question is no, it's not unreasonable. In fact retailers are legally required to pay your return postage costs for a faulty item.
"Your rights under the Consumer Rights Act are against the retailer – the company that sold you the product – not the manufacturer, and so you must take any claim to the retailer."
http://www.which.co.uk/consumer-rights/regulation/consumer-rights-act
So I wonder if I should've been making warranty claims through Amazon rather than Garmin directly? This would've netted me new replacement items too, rather than refurbs.