So basically the old molds are too sloppy?
It's more like the cheap plastic doesn't cool the same way the expensive stuff does. I haven't seen any greater variance in runs with DX or D than I have with Champ or Z.
It's actually pretty easy to see if you look closely. The base plastics like DX or the old Tourney Pro shrunk out of the mold. The resulting discs have a smaller diameter and a less defined nose than the actual mold. Features like a notch or bead are also minimized a bit.
When the same molds are used in premium plastic, the plastic packs out and really shows the detail of the mold. The discs have a larger diameter, blunter nose and more defined stabilizing features than the DX versions from the same mold. Bigger diameter, blunter nose, bigger bead=a slower, more overstable disc. In the case discs like the Gazelle, the premium plastic versions had no glide and flew nothing like the DX versions.
Also, like I said before, the discs designed before premium plastics were designed to start out more stable than the intended flight. The base plastic beats in quickly, so the discs were supposed to start out more overstable than intended and break into the sweet spot. Once you convert to premium plastic, the discs don't break in. They stay like they were out of the box for a long time.
So a disc like the Gazelle has a double whammy in premium plastic. The plastic makes it even MORE overstable than the too overstable way it was designed, and then the plastic never beats in. So you really can't run them in premium plastic. As a result Omega Supersloth and the "I'm too evolved for DX" crowd will never throw a Gazelle, despite the fact that a well seasoned DX Gazelle in flight is a thing of beauty.
What is disappointing about this is that the natural rival of the Gazelle, the Discraft Cyclone, was recently run in ESP. The ESP Cyclone is the closest thing to a Tourney Pro Cyclone I've ever thrown. It opens up potential new life for that great disc. I would have like to see the Gazelle at least tried in Star before it was killed.