RacerX:
I can't believe outhaul would be 10cm out.
No insult intended but you are not measuring the distance along the boom arms or along the curve of the sail are you? It is a straight line from front of mast to clew (the longest inside measurement of the boom from front of clamp to inside the boom's pulleys)
None taken, measuring it precisly as per the rigging guide and checked that the numbers on the north silver boom are indeed correct, which is as you mention.
I also measured the masts, the luff, the extension...
Its only approx 10 cm out (maybe less on my blades) and varies across the four sails that I have. The significant point however is that, when downhaulled to spec, the boom recommendation is useless as there would be no tension in the outhall at all in the sail, I understand its a guide, but I would have though it be a usefull starting point that would at least rig a workable sail? Its more of you need to buy this size boom for the sail... [and even then its a lie]
Downhaul set to spec is a lot of downhaul on all of the four sails I have. With deep chevrons in all the three top panels and definelty way to much on the 4.2 that have. Perhaps the downhaul recommendations allow for stretching over time?
Just using luff length to set the extension and rigging the rest by eye (which I am starting to get, I am still a newbie to all this).