ive not done anythign that had to be acurate to the mm. in general, you wouldnt expect it to be better than .005" to .01" if that. or are you talking about an overal scaling issue where its simply the wrong size?
and for memory, if you cant go to 64 bit right now, try disabling the texture collection. thats often what causes the crashes during fusing. just pushed the memory a little bit too far, especially if youve got many passes (i sometimes have 70 or 80 being fused at once)