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Could this be an effect of using perspective projections instead of parallel in the preview? If your looking at a model from the top and it appears too large it may be because of the perspective transform in ReplicatorG's viewer.
The transform it's self is an unexpected behavior for a CAD program and should be corrected to use parallel projections by default and include an option for perspective.
It appears that the 210x210x210 build volume doesn't exactly visually turn out to be 210mm high in the preview. It is therefor likely to scale models just a tat to big, thinking that it will fit.
http://picasaweb.google.com/erikdebruijn1/UltimakerProtobox#5540613379363839778
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