Re: So this almost never happens...
But I am sure that if you had a sharper stick-you would have used it.
Back in the day there simply weren't the tools available (on s o many fronts) that we have today.
I remember working on a crossover for a loudspeaker a couple of decades ago and I was using a goo quality RTA (1/3rd oct) with fine resolution and I could hear the changes I was making-but the RTA wasn't showing any difference. I could not tell which part value was correct. Very frustrating.
It wasn't until I started using higher resolution measurement tools that I started to realize what i was doing.
The ears are a good final judge-but I would not want to start out using them.
But having the experience of using my ears over most of career doesn't hurt.