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Doug, I'm not sure chaning the mesh would buy you much and I have already had problems with people printing this in abs that are easily resolved by scaling the object by a half percent or so (see comments below). I did prototype this in PLA originally and with its relatively small shrink rate I can't think of a reason why it would ever print too large unless your printer or software is scaling it or otherwise not printing accurately in one axis or another. If you could would you carefully measure the outside dimensions of the long and short axis of the case and post your numbers here? Also some detail photo posts on the "made one" section might help understand what is happening to the nylon print.