Some answers, I think. But questions first.
You say you set the printer to actual size? what does that mean? I am trying to figure out what you had to print? There was a fair bit of discussion on the actual rib profile, just a bit ago (last few days of March-2016) I have shown that the CG is slightly different in estimation, but then clearly most understand, that a heavy top person vs heavy bottom person can affect the CG as much, or the simple fact of 160 lb vs 235 # pilot.
AT 60 mph, we have little measurable differences. i.e. there are far more efficient wings out there, but at 60 mph hour, the measurable differences are almost nil.
Lastly where are you measuring the 1/4" difference? Just curious.
Double lastly...There is simply no reason to require a second jib to pre-bend anything for the XL ribs, it can easily be done in one jib, one time, nothing radical or major here as for as 1/4" spruce is involved.
cheers
Scott