Hmm. I've printed them all out, without any problems.

I would say the first thing to do is actually take a ruler to the pieces, and make sure that all of them are coming out at 1" - both the corner pieces and the straight pieces.

I say this because the corner pieces are bigger (averaging around 7.6 x 9.5) than the straight pieces (averaging around 7.15 x 8.85). This would be consistent with your results (smaller corners) if the pages were, for some reason, being scaled when you printed them. So, find out which piece isn't being printed to the proper size - or if, indeed, both aren't printing at the right size.


Edit: I know you read through everything on the forum already, but double check the Page Scaling setting when you print, and make sure its set to "None". Your problem really sounds like it is set to "Fit to Paper".