I don't even think its Scott's fault at all
I think it is more the parts the hood mates to.
I believe the nose cone, side panels, and thingy my knees bash into are all Injection Molded. My personal opinion is its the cooling process after the shot fills the mold. Maybe its the size of the shot? Tooling? Maybe the post processing?
There are a lot of variables.
I know from experience making custom stuff for Scott's hoods for my friends and I that my templates NEVER match from sled to sled EXACTLY. I always have to make new ones, and I have done a bunch now.
I do know the nose cone templates i have match better than the side panels or the gas tank thingy. I think this is because of the thickness difference between these parts. The thicker part will cool slower than the thinner part. A thinner part(like a side panel or gas tank thing) will distort to temperature variances more quickly.
My opinion
Its not Diamond S, its cheap manufacturing and crappy quality control.
Here is what I did in the nose cone. I use factory holes, no drilling in nose cone. 5 feet of powder, no snow under the hood and I like to play Das Boat.