Love hearing about your adventures. Keep on posting...

Yep, nothing like actually building something to show yourself where the perfect clashes with reality. Made more than a few miscalculations in my projects and had to find a fix. Good teaching lesson for the minors. Figure out a fix when things don't work out as planned. Probably a valuable life lesson in there, too.
I don't know what went wrong, but your build is looking pretty nice to me. You and the minors must be pretty happy with your progress.