I have yet to single car that does not have some sideskirt overhang for either the front or rear wheel well, so the "Ford tolerances" excuse does seem like pure BS. Especially considering the basic design of the sideskirts on the 05-07s seems fundamentally the same as prior body models.
This is one of the only things that annoys me about my car. I wonder if the skirts can be adjusted to split the 1/2" overhang between the front and rear wheel wells, so there will be only about 1/4" for the front and rear wheel wells? Has anyone tried this?