Bob
I fully agree with your comments about the fit of "old stock" Healey wings from AH Spares.
I think I can safely say that over the last few years we have not recieved a panel from them that did not need modification in some way.
The worst "offender" was the rear seat pan panel which was 2" too wide. The only solution was to cut it down the middle and then trim the sides to fit, and then weld it back together. Not the ideal solution.
This, however, is not an unknown problem to Healey owners, because, as you correctly point out, Healey's were assembled in the Factory on a "best fit" basis from large parts piles.
We were "fortunate" in having a small supply of genuine Factory spare wings from the 60's, and even these require some work in order to get them to fit correctly.
It is unfortunate that Aluminium Panels, from this source are a very poor fit, probably worse than their steel conterparts.
As you found out to your cost,it is always better to try and repair your original panels. This may be time consuming and more expensive, but at least you can be sure they will fit!.
We have spoken to AH in the past, at great length, about the poor quality of their panels, and I think what they are trying to do now, with the establishment of a "new Company" is a step in the right direction.
I'm afraid at the end of the day "The proof of the pudding is in the eating" - (Old English Phrase), i.e. we can only try them before commenting further.
Interesting Thread.
Cheers