I would think that the plans, regardless of how they were cut, are a little off. I can't say who caused it , Roy or PKC but that's got to be the issue. I do know that PKC offers two types of kits, Hand cut and Laser cut. The hand cut kits are the older style kits. Perhaps that's what you have. Larry K. is an upright guy so I think he will make good as best he can. Good Luck.