Regardless the cost of the actual chips in a Single is going to be a pretty small part of the $1300 they charge for it. While having to eat whatever the cost of the wafers was will hurt their bottom line, going from 8 chips to 7 chips is not going to be a big cost savings.
While this is undeniably true, things which change your financial projections are a big deal and can have massive implications for the future of your company. While reducing the number of chips per device doesn't significantly reduce the cost per unit of those devices, it does allow you to build significantly more devices at $1300 each (or to fill more orders which have already been paid for). If they can scavenge 16,000 chips out of the 74,000 by reducing the number of chips per unit, that's 2,000 more Single orders which can be filled without having to order additional chips - that represents an $2,600,000 in revenue for the first production run, which is significant by anyone's criteria.
While BFL is a bit of a black box in terms of information regarding its funding sources, nothing they have said suggests that they have access to a bottomless well of cost-free money. One way or another, these delays are costing them significant money and they have to find that money from somewhere - whether it's from pre-orders, selling equity, or loans. Whatever money they're spending now on unanticipated costs is money which won't be available for something else in the future.
I agree that Josh has appeared not to know a lot of material information until the last moment, but it's been obvious for months that Josh is not directly over-seeing this project and that he gets much of his information second or third hand. Josh being unaware of something doesn't mean that those actually involved in the step concerned had incomplete or inaccurate information (hell, Josh seemed surprised to learn that piddly little orders aren't going to be given priority when it comes to facilities allocating production time at short notice).
BFL customers have been somewhat over-involved during the last 9 months. How many chips were being produced/had been ordered is not information which would normally be shared with customers, especially when no information has been given about how many of each unit type are going to be produced from the first 5,000 chips and the following 6,000. People have reacted to this over-sharing by feeling entitled to have a voice in the business decisions made by BFL.