Well, I need to explain a bit more. Did some research on the AC's. A friend bought an AC for his 2000 KX. It looks great and everything fit perfectly. I have a '98 and I had just received my AC but hadn't installed it when I posted the last message. The sub-frame is made of larger diameter AL than the stock. The '98 is round tubing vs. the square on the '99 and up.
My sub-frame mounted up perfectly, but the plastic didn't fit perfectly and one of the threaded inserts came out.
Contacted Mike at AC and he took the frame back without question, fixed the threads and double checked the alignment. Had the sub-frame back in two days. The plastic is still a little off, but not as bad.
The answer to the alignment differences between my friends and mine was this: The round tube frames have to be heat treated and they sometimes warp. The square tube frames don't need the heat treating, so there is no chance for warping after they are welded.
In any case, the mis-alignment on the left number plate was slight and AC indicated no reservations in taking the frame back if I wasn't satisfied. Mike even said I could try if for a while, and if I was unhappy, he would refund my money in full.
Since you need a newer square tube sub-frame, I would recommend you give it a try. You'll save quite a bit of money and the frames do appear to be of quality construction.
That said, if you need a round tube frame, you may want to consider another source. If I do have any more trouble, I'll probably be contacting BBR to see what they offer for my bike.
Good Luck