Every single thing makes a differences, i do remember that an ex IAF officiall was saying how a loosely tight screw gives elevated RCS while testing F35 in US. Funny part is he quoted this to undermine Russian capability to bring stealth in FGFA.
Stealth aircraft are RCS tested after maintenance. Plus panels are designed in such a way that they fit in seamlessly from the start. A pilot also visually inspects the aircraft before flying it, paying more attention to whatever was worked on by the ground crew.
People make whatever excuses they want just to not support what they don't want to support.
Think about it this way, the IAF is happy with the Bars radar and think it will remain useful for many more years. The F-22 and F-35 are still flying with analog AESA radars. But everybody has a problem with the Russians already operating better tech than what's on the F-22/F-35, ie, a generation ahead of the Bars, which even the IAF is fine with, and on an aircraft that's as stealthy as the F-22/F-35. And the Russians claim the Su-57 is much cheaper to operate than the Flanker, which gives it an advantage over the F-22.
The Su-57 is a real 5th gen aircraft, and new variants with modifications are coming in. There will be a Su-57M, even an M2, and a Su-60 and a Su-63 and a Su-64 and all successive models will be more stealthy than the one previous to it, all within a decade from now, and all more capable than the F-22/F-35.
People have consumed so much Western propaganda that even Western analysts have started taking back their criticisms of the Su-57.
People are yet to see the final version before true RCS tests can be conducted by outsiders.
