Hi Rob,
That's not the issue. I did indeed encounter the problem late last year that my calibration frames had the wrong size suddenly, but I used a more pragmatic way to solve this; I cropped the two top lines.
Yes, dirty, but it does the trick.
Anyway, the flat frame in question (I actually tried different ones) have been created afterwards and have the proper dimension.
On a side note, I tried the new weighted preprocessing script a while ago and had the same issue that flats over-flat the image and stopped using it, but now the calibration does the same...