Just wanted to add that my 2nd refit is pretty much perfect, it came in weeks before the baby but am now starting to get some time in as Molly naps.
I think what is occurring is that JH makes the bores slightly smaller than the actual impression to accommodate the hard acrylic not having much give, and making them easier to insert and having less fit issues. However, if it's too small you get a loose fit and squelching when you open your mouth as well as other minor issues. Sensaphonics and westone are actually able to make their bores thicker than the impressions because they are a softer material that is able to provide some give and accommodate your inner ear much better for a tighter more sealed fit. Regardless I am extremely happy with the customer service and quality of sound, especially straight from iPod/pad/phone.