This question has come up before on another forum. People who have been around for a while will have their favorites and probably most of these "favorates" show up on Bob Hunt's list above. Gene Schaffer certainly deserves at or near the top of any such list.
For the record, in addition to Bob's list above, here are some others who have finished second in the Open event at the Nats but never won:
Robert Haren ('59)
Thorton Hoffman ('53)
Charles Lickliter ('61)
Dick Mathis ('67)*
Charles Reeves ('66)
Gerald Wagner ('57)
Malcolm Windham ('56)
J.C. Yates ('47, '48)
Notes:
Some familiar names and some not-so-familiar names. Interesting.
* Dick Mathis had high flight points in '64 but finished 4th with appearance points. His moodel was covered and trimmed with Jap tissue, all clear dope. I thought the airplane looked really good, but he took a beating on the appearance points.
A Senior (Dennis Adamisin) won the Walker Cup in 72 because appearance points are not included in the flyoff score. I do not know if there are other instances when the Walker Cup was won or lost because appearance points are not used in the flyoff score.