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I'm assuming poll size tells the machine to measure the paper? You still have to remember there is going to be unusable space at the end of the paper that the rollers hold onto and the machine is not going to account for this because in the vinyl world you don't worry about how much vinyl is at the end, you are just going to cut it off and continue to use the roll. You are trying to use the machine as a plotter, which is not what it was designed for and thereby missing some of the abilities a true plotter would have. You seem to be getting pretty close to your goal, but as you've discovered it's just going to be a matter of trial and error to find the settings and conditions that work for you.

I have never tried to draw on sheets or ever use sheets with my Graphtec. But have you calibrated the cutter to the cutting software? As in cut/draw a 3" x 3" square and make sure that it measures exactly at 3" x 3"? That adjustment is in Resolution. Mine is set at 1016 in/steps. I have a FC7000 and FC8000. but the same adjustment is made in Resolution in my cutting software.. I use Flexi software. And Graphtec Pro Studio, which is also Flexi software. So you are putting your cutter head exactly where you want it and you are pushing the ORIGIN button on the cutter? You must push the Origin button before sending a job. That Origin point is the measuring point for your design. Most people here are cutting vinyl on 15"-30" wide vinyl rolls. Only a couple hand fulls answer questions. Your cutter will not cut past the pinch rollers unless, you use expand or turn off the pinch roller sensor. I don't know of anyone on here, doing what you are trying to do.