I did another test. I placed the 4" (101.6mm) object back into Cura. Upscaled it to 101.6mm (from 8mm) and it tells me that is 5.62% increase in size. So in theory if I take each piece of my final project (which is a total of 4" around) and upscale each piece by 5.62% everything will fit together correctly?
Just wish there was a way to get this to work right. 3dsmax doesn't give really any options when exporting STL format. Just a selection of Binary or ASCII, and rather to export all or selected.
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gr5 2,267
Easiest thing to do is to scale up by 25.4 in cura but I'm sure when you export to STL there is an option somewhere to do it in mm units.
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