Jon,
Imho, isn't it possible that the AE simply DIDN'T put much effort in trying to obtain relatively similar sized blocks to form the courses ? I am convinced that the biggest part of the courses was laid 'very fast' and that this fast-laying of the courses, not an accurate construction of the courses, was the main goal. The precision-work started when the courses reached the locations in the very core of the monument where we now can observe the chambers, galleries, 'air'-shafts and relief chambers. After the completion of the apex, new precision-work started, namely, the placing of the casing stones.
Ronald.