I read back though your post and PMs. A couple of questions come to mind. Has she grown in any primarys that were normal? Any way to tell if it's the same feather follices that keep producing the deformed feathers? She had surgery on the right wing. can you tell if it "fixed" the issue with those feathers? If she could have some of her flights then ,yes ,i vote to have them removed. If any new feather that comes in is being replaced by a deformed feather then ,I'd keep trying to find the cause. It's strange this is only occurs on the wings ,if the cause was disease, you'd think it would effect feathers else where. Sorry ,wish i had the magic answer ,but i don't , just more questions. Are we sure about the PBFD test? It can sometimes come back negative, even in birds that have it. The comment about "soft beak" worries me.