Okay, so I found the problem... And it was an easy fix....
It was me :X
I remeasured, and noticed a chamfer on inside the tread valley (I guess to reduce stress concentration).... My caliper was resting on the chamfer, not completely seated in the valley... Measured from the center of the valley (not on the chamfer) - everything is nominal...
Side to Center to Side - everything is within a couple thousandths
I'm good to go for another 25K miles, at high pressure and even wear
Sorry for the bad call
Thanks for the help