This has to do with the correct width count of the letter charts. As Margaret stated back in December, GHI, JKL & PQR do not have their width correctly stated.
Specifically, H is 72 wide - the flower tips; JKL are each 72 - flowers and leaf edges; and P is 72 where bird tails and the bottom of the cage all extend beyond the cartouche. Additionally, I had discovered and noted that E is 71 where the top of the chair extends outside the design area. But, wait, there's more! Last night I found that N is really 74; birds tails again. I hadn't noticed it, but M goes over as well, by two, making it 72 - fingertips of the mermaid. O has leaf edge problems too, making it 72. V is 71 - upper left corner the leaf edge and vine go over. X is 72 with flower tips, table top and leg and again, chair top causing problems. And, finally, Y is over by one, making it 71 - the yarn loops take it outside area of the cartouche by one.
So, to recap, that's letters E, H, J, K, L, M, N, O, P, V, X, and Y that have problems with their widths. ALSO, L, J and H (caught by Margaret) are 101 high. I counted all the rest and only came up with U to add to that list. Thanks to Margaret and Nic for their help earlier.