Jon
I experienced this same scenario with these hinges. After finding an original hinge and did a layout of the aftermarket hinge lever I discovered is out regarding the offset and twist. As you had stated this minor amount at the hinge is amplified at the latch side. The aftermarket hinge frame is the only thing useable.
I had a similar issue with the aftermarket brake drum. Way out of round. My guess is the casting was not stress relieved prior to machining. Luckily I found some NOS drums.
