Any chance the blades are icing up? I've had a similar situation with controls and I was getting ice build up on the edges of the rotor blades. Temperature was slightly above zero in my situation and a fog bank was rolling in.
I had a similar issue; however, it was at sea level and a fog bank was rolling in. Temperature was around zero. What I found was a thin layer of ice building up on the rotor blades leading/trailing edges. Any chance you are experiencing icing of the blades. Icing would change the profile...
Although interested on the ability to inspect via NDE I am not sure of this method. Would suggest you not use the liquid penetrant on the blades. Some penetrants, cleaners or associated developers may not be compatible with the plastic and could cause unexpected issues such as degrading plastic.
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