How often do you actually get a chance to measure the gap under a real load with the car sitting at a floor like that, because static measurements with the car empty will lie to you every time? A full load changes the sill height, the car can squat on its springs, and suddenly that quarter inch you had on paper is gone. I've seen guys check the gap at the top floor with nobody in the car and call it good, then the same car at the bottom with weight in it is a whole different story. The bigger question is whether that gap was even measured at the worst case floor, because re-leveling only happens after the load changes and the car can stop anywhere in between. That lady probably saved you a callback or worse, and the spec sheet never would have told you.

How did you figure out your blocks were off, was it just the armhole or did other spots show up once you started draping? Curious if you're trashing all your old blocks or just fixing the shoulder and armhole parts.