>The freerouter also has trouble paying attention to the actual edges >of the >PCB and has a distorted shape.
No this is not freerouter's fault. It is mostly likely that your board perimeter is not proper in Kicad. You have to zoom in and make dead sure that all your "edges_pcb" type lines are contiguous, EXACTLY. That is the ending point of one line or arc must be EXACTLY the same point as the next line or arc's starting point. If you click on a line, the status bar should tell you the exact endpoints of the line in coordinate space. Walk around your board and tie them together please. Dick
