could you repost your alternative?
i missed it
i did find that origin pin 1 seemed to nail the issue and make no gap
even in gerber 2.4
my gap was i think .005 mil

in the (bad) case of using center origin and using gerber 2.3 i think
the 
result was a 2 mil gap as the edges of the pads were pulled back toward
the center to the nearest mil

this notwithstanding it has proven to be a useful and clever tool

Dennis Saputelli


Abd ulRahman Lomax wrote:
> 
> If gerber plots were not rounded off, there would be no problem with the
> "virtual shorts," and, in fact, if fab houses fabbed the boards as-is
> without modifying the gerber, there would also be no problem.
> 
> But Protel does some rounding and it is not easy to exactly control
> aperture assignments while using the much easier RS-274X, though it can be
> done; properly implemented, aperture match would cause the gap to actually
> disappear as long as the pad distance is such as to leave the pads on a 1
> mil grid. But as Mr. Saputelli discovered, it is fairly easy to set up and
> place a virtual short footprint in such a way as to leave a tiny gap,
> enough to puzzle the fab house inspector.
> 
> Complexities like this have led me to recommend the alternate method I
> indicated in another post in this thread. It is a little easier to document
> and no fab house will be tempted to modify the gerber.
> 

-- 
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