So here are the last two emails that went back and forth.
Well, I've emailed Performance Machine, Avon, Kuryakyn, and Joker Machine. They all note that they make their grips based on the stock measurements. Then they physically measured them for me. They are all within 1/10 of an inch.
Then I emailed a few of the custom bar manufacturers and asked about the measurements, (without giving your name, or the Carlini name) and they all responded with the same. That the bars were cut too long. When I emailed the pictures and asked of a solution, again, they all responded with the same. The bars have to be cut, noting that much gap can't be made up anywhere. 1/8" maybe, but a half inch isn't doable.
Have you been able to recheck your jig and remeasure?