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Hmmm, the thing about "upgrading" the scanner being at the root makes me wonder about whether the scanner is indeed the problem. Have you scanned some ruled graph paper at a specified dpi and then compared it against the measured file properties on GIMP: e.g. scan 1 inch square at 300 dpi sb a 300x300pixel square on the final image. If not, then you may have found a certain optical error in the way the scanner works (could be an aspect of newer "cheaper" scanners). I can't think of ever working from a scanner in a way that matters (such as parts) so I haven't noticed a particular problem from my scanner. Since scanners are not that sophisticated optically (a kind of "contact" print) I wouldn't be surprised that there may be accuracy issues on home scanners I haven't noticed before.
If the scanner is doing the distortion, is it repeatable? If so the fix might be to just re-scale the image by a corrective amount. Ugly fix, but probably workable.
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La maquina sobre mi escritorio es una "computadora" del latin "computare", no un "ordenador". El estado de mi escritorio afirma eso. (yo)
http://constantvariation.blogspot.com/
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