[Jon Stratis]

The problem we had with the old school sizing boxes (which half the teams in FIRST have probably never seen, and no current student has!) rarely had to do with robots being square. The problem there were the "minor protrusions" that would prevent them from physically sliding into the box. The language around "minor protrusions" is still present in R02 for determining the frame perimeter, and with bumpers on won't be a concern for measurement purposes.

On a historical note, you will find that the "minor protrusion" language has been in the frame perimeter rules for a long time (Since 2011's R14, I believe), but wasn't included in the robot size itself until 2013 (R02/R03). 2013 was also the first year we didn't have a physical sizing box the robot had to be jammed into.