I'm not surprised by this at all, I tweak my basal and bolus quantities/ratios fairly regularly as it's clear my insulin requirements vary a lot day to day, even when on paper, my activity levels and food are the same. It's like herding cats!
Its why I get very cross when DSN's and the like imply that it's all just a matter of simple maths and any problems are "user error". They seem to be under the misguided impression that all we need to do is count CHO accurately, inject the exact same bolus ratio and stick with a fixed amount of basal and it'll all be fine, no highs and no hypos. If only!
I might print out this post and bring it to my next hosp appt. as it illustrates beautifully just how much variation there is. thanks Tim!