SplinterGroup
.... you didn't make the corner blocks leaving you with both sides of the cross bar on corners (or did you edit out that step???)
Not sure what you mean by that Splinter.  The corner blocks need to align on the same side of the cross bar.

I gave my "old new one" to my friend so after updating the SketchUp for uploading to the 3DW I decided to make a "new new one" and cocked it up.  I forgot that the last version had a bug which I only fixed in CorelDraw and didn't retro fit to SU and repeated the mistake again.

The bar has to snug up to the corners on both ends,

however, I found there was a gap on one end,

which naturally gave false results.

It turned out that the gap between the rod and the t-bolt anchor was out of whack,

and had to be changed back in SketchUp and carried forward,

through to the laser.
After all this BS, the bottom line is that if anyone was crazy enough to download from the 3DW, there is an updated version sitting there now,

FAIW, it felt good to track down and correct the bug.  Being able to manipulate the angles in SketchUp sure beats trial and error in the workshop.
 

If your first cut is too short... Take the second cut from the longer end... LBD