What I wonder is, how much difference would the average rider notice between say 42 & 37mm offset when the frame is designed for 37mm offset?
A little, not a lot. The idea that a bike is specifically designed for one offset or another is mostly marketing. Offset modifies the handling, you might prefer it one way, or the other.
For example: Not long before SBG launched, offsets were generally much closer to what Transition said was the SHG offset preference. Then, in 2016 Rockshox decided to add 4mm to everything 27.5/drop short offset 29 options (who knows why).
In 2017 Transition come out with SBG which is a revolutionary shorter offset… Except that the new short offset was only going roughly the same amount shorter vs the pre-2016 offset as RockShox had made you go longer the year before, and I bet most people didn’t even notice.
Just for clarity I realise the above might be confusing…
MY 2016 Offset: 42mm
MY 2017 Offset: 46mm
MY 2018 Transition Offset: 37mm
Yes the leap from 37 > 46 is pretty noticeable, but most people probably never even thought about the difference between 42 and 46.