I hear you. I've been trying to do a Pole Position cab in SketchUp from Jakobud's plans
and a broken cab, and still run into some problems of not adding up.
However, to bring it into prespective, a quarter inch difference over a total of 64" is less than half a percent off. Not bad for hand messurements; in fact that's very good.
Part of the problem is the numbers shown on the plans probably are not really exactly 18.75" (or whatever), but something pretty close that it looks like that. Are the numbers with or without (rounded) T-molding? Were the vertical & horizontal calculated from angle + length, or plumb bob and right-angle?
Part of
my problem is the original cab I'm going off of is damaged (the whole reason I'm recreating it), so sometimes I'm estimating plus or minus 1/4" over about one foot, and +/- 1/2" over three feet. That's closer to 2% and 1% range of error. I've tried
fudging the numbers adjusting it in cad, but everything I've tried has looked a little off to me.
I'm not sure how good or bad the cab the numbers jakobud got was, but add the not-manufactured-at-easy-fractions to the hand measuring of possiblely bad cad, and 0.4% error isn't bad at all.
I know, not the answer you wanted.

But just saying jakobud's plans are damn close, so try fudging it around in cad. And I'd rather have the raw, but doesn't add up, numbers, than numbers guestimated at so they do add up (but might be guestimated wrong) and passed off as prefect. (Some day I'll get off my backside and just do it, too.

)