More seriously, if the sizes are only off by half a pixel on the computer, but 1/8 inch off when printing, I’d suspect printer scaling as was previously suggested.
The only print option that worked for us using Adobe Reader and Windows was to choose “Actual Size” to get the correct 6.5’’ x 6.5’’ output. “Scale 100%” (as suggested in the documentation) produced a 6.125’’ x 6.125’‘’ in our first print run.
Ours are 6.5 high and 6.4 wide. Not sure how team printing could effect what we’ll see on the field. Are you doing some sort of fudge-factor calibration?