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Well I just sold my NOS nosecone and I would have to disagree with you about the factory ones being sloppy. Mine still had very nicely done lead work and the spot welded area under the bumper strip looked very nice also.
I also wonder what these repro guys used for a template. Did they take measurements off an NOS cone? I doubt it, likely got measurements off one 30 year old cone thats been bumped a few times.
I'll take a real cone that needs a little work before I'd take a repro.

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NOS doesn't mean perfect, it just means 'New Old Stock". I've seen NOS parts that look perfect and ones that look worse than used..

From what I remember Gene told me (25+ years ago) that he made the patterns off of perfect undamaged noses.
Back then he was having them made on an English wheel, he may have had dies to stamp them out since then.