I spent many years thinking everything in audio could neatly be measured and quantified. If fact I am pretty anal retentive about this beyond just audio but I am slowly realizing that we don't always get the whole picture from text book measurements & analysis.
This is a good topic for an article that I plan on writing when I find the time.
I do the most exhaustive testing in amplifiers that I've seen compared to any publication. I've even spoken with the folks at Audio Precision and they were impressed with my methods. I am still not 100% happy however as I'd like to do more but as you pointed out, my time is limited and I am the only person on staff that does amplifier measurements for Audioholics.
Distortion audibility is a complex topic one that the folks at AP also discussed at our 2008 SOTU event in this rather boring but interesting video:
Audio Precision Amplifier Testing Methods Class — Reviews and News from Audioholics
Again sometimes text book theory doesn't always apply to real world. I found this especially true with loudspeakers and somewhat applicable to amplification.