Thanks for the offer.  I went through all of the $DRAWSEGMENT entries in the 
.brd file for layer 28 (PCB_EDGES) and found that there was one extra segment 
and the segments were not contiguous.  I painstakingly went through and created 
coordinates for each board, filled in a spreadsheet and then had Excell export 
the spreadsheet so that I could put the segments back into the .brd file.  
Everything worked perfectly from then on.

In the future, I will probably use this approach to start the .brd file with 
precisely-defined edges.  It's a lot easier than trying to draw them out in the 
board editor.

Thanks to everyone for all of the suggestions!
Greg



________________________________
From: Dick H. <[email protected]>
To: [email protected]
Sent: Thursday, June 18, 2009 3:19:09 PM
Subject: [kicad-users] Re: PLEASE help....Anyone out there???

--- In [email protected], Greg Dyess <gregory.dy...@...> wrote:
>
> Ahhhh, now I see what you mean.  I will double-check this as I know we had to 
> go back and touch up some of the board edges after the entire board was 
> drawn.  This will probably require hand-editing of the .brd file.


Greg,

If this does not lead to anything, then email me your board file please.  dick 
at softplc.com 

I will step through the code with it and see why it it not converting properly 
to DSN.

Dick




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