I was having a bit of a think and I think the answer may be poor quality control.
I've worked in injection moulding before and one die often produces multiples of the same object; so for each pressing you get say, 4 badges. This saves production time. If Holden wanted a large quantity of Torana letters it's likely there'd be more than one set per die and prior to CAD, tolerances weren't as strict as they are these days so you could have say, 4 different versions of the same letters.
I'm not sure how many sets per die the repro co. used but my guess is there is one set of letters per pressing rather than individually pressed letters. It could be there's a dodgy A in the die or they've thrown in some duds from a dodgy pressing into the batch.
My guess is the QA person 'passed' the dodgy A (there may be more than one out there) and put it or them into packs with regular A's hoping nobody would notice.
You may have just been lumbered with a dodgy casting. I'd take it back to Rares and ask for a replacement set and see if the letters are the same in another random pack.
s
Edited by StephenSLR, 28 January 2016 - 10:57 AM.