maybe this particular peice is more fubared than the usual aftermarket metal. like the guy on the line at the factory was having a smoke and talking on his cell phone trying to figure out where the beach party was that night when your front clip rolled by.
exchange it. i know you know that these peices dont go right in, but if it is really as big of a pain in the ass as you say it is, perhaps this certain peice is fu@&ed up beyond all recognition.
good luck.