KevinS, you are not having good luck. Sorry for the less than expected experience with your sledge. As most of you know, plans are taken to a facility where they are copied from a master. Unfortunately, any copying within 2% is considered good. The sledge plans are approximately 48" long, a complete 2% error could result in a .96" deviation from actual size. Most always the plans print out right on scale, that is the reason for the ruler at the bottom of the plans, to make sure they are correct. In your case Kevin, they were not and it should have been caught before leaving Morris. Mistakes happen, that does not justify it but it happens. I recommend you contact Morris and handle this problem, they usually make good on kit shortcomings. I am confident in its capabilities but I cannot control kit quality. I hope this at least makes you feel better about your experience and that all future dealings with Morris kits will be more of the norm. Feel free to email me at [email protected] if you have any questions. Thanks, Jeff Williams, sledge designer.