When you find the thumb shape that is just right, see if your pro shop will be able to take a mold and keep it on file with your drill measurments. I was unaware that was possible until the pro in The Sports Shop at Brunswick Zone Hazlet offered. I was having similar problems for a while. I had one ball drilled when weather was warm, another when cold, I didn't know how to relax my hand through the swing. As a result I had more thumb hole demensions than I knew. I could bury the thumb relax and roll with one ball. Another fellt snug and I tended to half bury the thumb, tobbien me of revs. Another the hole was too big and I tended to grab the ball.
Now they are all identical. Same delivery for every ball.
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