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So I'm starting to paint up some Ork boyz, and I've got a mix of two new boxes of boyz and some sprues that came with the Eye of Terror "build-a-mutant" kit.  The older sprues are a lighter shade of grey and have less detail, edges are a bit rounded, etc.  The newer sprues are a darker plastic and have much better defined detail.

It seems that the ork boyz have already gotten a retooling - has there been any confirmation that the boyz are going to be redone at all?

I don't know, I had the same thing happen to me when I got a Mordheim box set from England. The detail on the minis was quite bad, and there was a horrendous amount of flash. I later punchased a copy at my UFLGS, and the miniatures were nearly perfect. Well, as perfect as the monkey-dog skaven and Pirates of the Caribbean extras can get.

It's basically a production snafu. The way the plastic is mixed determines both color and detail. The lighter the color, the weaker (softer) the plastic and thus the less detail it has. I got the Dark Angels infantry sprue and the details are sharp and crisp as anything you'll ever see in metal. My Black Templar bits are soft and rather bland looking by comparison. The DA sprue is very dark and the BT sprue is very very light colored.

That explains the Fire Warriors I got about four years ago.  I gave up in frustration trying to paint them, as paint ALWAYS ran into the armor seams.  I noticed that they were kind of squishy-soft looking as well.