James, I seem to remember your .25" bit was in database as EXACTLY .25", are you absolutely SURE the tip measures that? Sorry to sound like a broken record, but not a single one of my 1/4" bits measure .250". Also check material several different places like Gene says. TJ normally has 3-4 different versions of his ply files and the only thing different is ply thickness. Glad things are better, but the only thing you should be having to change is your pocket allowance depending on the type of fit you want.
scott P.
2013 Desktop/spindle/VCP 12.0*
Maine