I have a board design that I have been trying to export as a Gerber, but every time I do, the Gerber outline is larger than it's supposed to be. I know that silkscreen or other items outside the board dimensions will do this, but I've confirmed that this isn't the case. Here is the board in Eagle (6.5), with all layers enabled, so you can see that nothing is outside of the board outline:
Eagle automatically cropped the image because there was nothing outside of that area. Now, when I export the Gerber files, this is what I get:
The padding on the left and right appears in every Gerber viewer I've used, so it's definitely in the file, not just a rendering error on OSHPark's end. After some messing around, I've confirmed that it's due to the QFP footprint and that it only occurs when it is rotated 45 degrees like that. I made that footprint myself, and it is only SMD pads, no labels, no keepout, just the pads. So why is the Gerber export so badly screwing up the board outline? It only does it for the top layer, the bottom layer is the correct size. Any thoughts?