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In the production manager section there is a parameter depicting the percentage of the original size. Make sure you set it to 100%. Also drop down the margin to zero in the same parameter. When you open up the production manager so the dialog box appears, try to scroll alongwith the panes and you will find it. I will send you some screenshots later today. Regarding the non closure of the cut and skewing of the line, it looks like it is the issue with the offset of the blade. You need to play around with it till you get the desired result

New test and new better result.

Take a look at this, especially Wildgoose's comment

overcut needs added a little to join lines. Offset is to square up corners. Run a TEST cut from your cutter TEST feature first. I have Flexi and Resolution should take care of the sizing. Type a text on the layout screen then click cut so the screen opens. Upper Left corner Properties... screen changes, Top choose the KNIFE tab. last to the right. Default Job properties. Resolution. This is from Flexistarter, but should be close to yours. Resolution is how many steps in an inch. Make a 4" x 4" square and adjust for it.

Many thanks for your words of wisdom. I'm looking forward to the screen shots as i'm desperately trying to get the job completed. I would really appreciate it if you could also send me some screen shots of the offset blade settings so that I can tweak it and hopefully i can get the final cut to join the line. The last thing I want to do is make matters worse. The software and plotter has never given me these issues before, so I've not had to adjust these settings in the past. Apologies for not having any visuals to show. Thanks once again.

Many thanks for your advice. The machine is pulling from the roll but there is no tension which would suggest the pulling. Nevertheless, it is a good call and will try taking the vinyl off the roll and see if that makes a difference. Thanks once again.

The size problem is likely a calibration issue with the software. Some place in the software there should be a setting for steps per inch. You will need to calibrate the software to your cutter. Is the cuts not joining, stopping too short? Or is it off to the side a little. If stopping short you can fix that by adding a bit of overcut. If not lining up then that would be a tracking issue. Are you pre-feeding your vinyl? Don't let the machine pull the vinyl from the roll, you don't want the machine working any harder than it has too.

https://www.ebay.com/itm/Jakar-Green-Self-Healing-Cutting-Mat-A0-A1-A2-A3-A4-A5-Double-Sided-cm-mm-Inch/201601371768?hash=item2ef060ce78:g:x~cAAOSwH9tbR0- https://www.ebay.com/itm/Cutting-Mat-Self-Healing-5-Layer-Reversible-A0-36-x-48-in-Green-Black-Graduated/193891325878?hash=item2d24d2d7b6:g:VoYAAOSwFE1gKAGK

https://www.ebay.com/itm/A0-36in-x-48in-EXTRA-LARGE-5-layer-Self-Healing-CUTTING-MAT-Reversible-IN-and-CM/163681921063?hash=item261c33e827:g:Bd8AAOSwmrpc00A1

I dialed it in and not bad - just not as smooth and quiet as I have grown accustomed to - reminded me of the old p-cut. it cut ok so I boxed it back up waiting on it's forever home after a rehoming fee of course

Are these plastisol, inkjet or what type of transfer? Where did you get them?

close - took shirt off and big belly hides shorts giving that appearance lol - sh*t happens

The ad says "Discontinued by manufacturer" Every ad that I have read about this cutter says "Support Corel Draw output directly". Nothing about which cutting software it would work on except WinPCsign Basic. (They have on ad) But this same company does have a regular website. Maybe contact them. Looking at Signcut software, they do support this cutter. Flexi software also supports this cutter. According to Vinyl Master list It shows this. That would have to be purchased at the VinylMaster.com website. SK 1100H, 1100ds, 1350H, 1350ds, 1600H, 1600ds, 720H, 720ds, 850H, 850ds, JK-1100, JK-1350, JK-720 You could try it on trial Signcut Or Vinyl Master https://www.sign-in-china.com/products/16171/24_quot_vinyl_sign_cutter_with_automatic_contour_cut_function_bluetooth_output.html You stated you got the cutter cheap, so get yourself a good updated software to run it.