On the top right of the page under the "Actions" tools you can edit this thread. I suggest putting this in the "Sheet metal" section not the "surfacing" section.
Good afternoon Emmett,
Welcome to the Board.
First I leave the bend allowance in the SW default. The bending we do here is not high tolerance.
The bend allowance is set at .50 and that could be part of your issue.
I did a sample model and came up with a 1.006 edge of flange to bend line dimension.
I used the Sheet Metal Base Flange (6.0 x 6.0) then added Edge Flanges to the outside edges, check the correct box for material inside, outside, etc..
Then use the Close Corner feature and your final bent pc should have very limited gaps, and you can control that feature,
At our shop, we use K-factor = .2733 and make the inner bend radius always the same as the thickness. This way, a 1" flange bend line will be 1" from the edge on the flat pattern. works every time.
Emmett, if you use a .259 bend allowance setting, I assume it is actually a bend deduction as shown in my attached picture. You should use a bend gap setting as shown to achieve a 1.014 (actually 1.015) dimension as you show.
gapsetting.JPG 161.8 KB