Both of my previous roadsters (MK2 and MK4) had issues with poorly fitting radiator aluminum. It seems that FFR shapes and bends it to almost fit a donor radiator, even though most of us use aftermarket radiators. Their radiator instructions say to offset the thing 5/8", presumably to the left since the idea of the offset is to let the rad cap have some room. Anyway, my FFR radiator is centered. The left side aluminum piece fits but the right is not even close. Moving the rad to the left will only aggravate the problem. On my MK2, I had give me a second left side panel, but bent to mirror the other left. On the MK4, I used Mike Everson's aluminum panel and got rave reviews on it. On this FIA body, Mike's panel is not an option. It looks like I can make new patterns and bend some new pieces.

I have two questions:

Why do these particularly visible pieces have such a terrible fit? (somewhat rhetorical)
Have any other FIA builders gotten to this point yet and what have you found?