Minor symbol variations in size / placement aren't surprising at all really - pad printers wear out a lot faster than bronze casting masters, and we are talking about the 1980's where stuff like art / stencils were often made by hand, traced from a master proof sheet most likely. Pad printers also can warp the more they're used, so that can account for some variation, though not drastic size changes.
The whole 'two completely different toolings' for flutters just ... baffles me. There had to have been a reason because it would have been quite expensive, but we may never know what that reason was. The big head versions don't even stand that badly, or at least the small head versions aren't substantially better.