This time ended up with more desirable results. Thanks to a newly acquired digital caliper, I was able to more properly set the calibration parameters. In the end, I had to still guess some values because of how sensitive the variables were. While it still isn’t 100% perfect (we’re talking about less than a percent off), it is enough to do what I need it to do. Maybe later I can calibrate it better but it is no longer such a high priority.
While the corners are still funky, with rounded projects, hopefully that will not be such a big deal.