Steelforbrains,
You are right to be pessimistic (I think all engineers should be by nature). Like any other FEA application, there is a learning curve to using CalculiX. Much of what we are talking about here are issues regarding usability that one would encounter when installing and learning to use Abaqus from the command line. There are sure to be bugs as well (the glut error probably is one), just like with any other software application. The benefit that an open source application offers is that the users who find the bugs are able to provide the fixes. You can also browse the source to see the actual formulation for an element, solver, etc.
My time contributed to the CalculiX project eventually shows up on the same balance sheet as my license costs for commercial codes (I just paid my bill for a commercial app). Before I started working on CalculiX, I spent a few months downloaded and evaluating quite a few other applications. CaluliX is the closest to meeting my finite element analysis needs, though it may not be for everyone.
One thing that CalculiX does have, that I think may be unique among open source finite element analysis codes, is a support mechanism. The user group is more responsive than many commercial support systems. If you want to get a feel for the usability, I would check out the archives on the Yahoo group. There are some very serious users. I will admit though that I am not using it exclusively for my analysis work. My customers often expect specific commercial applications, either ANSYS or Abaqus. I also work on a commercial FEA application (not one of the two preceding).
All that said, I guess I need to go back to bugs. Any application (including FEA) will have bugs. I have found them in every commercial FEA app I have used and I find them in CalculiX. Use all of them with care. The thing I like about CalculiX is that I can fix the problems that I find.
Regards,
Jeff