Hi Michael,
I have looked at your files and all look OK, I think the problem is with Lcam, its just not putting the compensation size (P) or a tool offset (D) into the code.
This is what I would do :-
Create your programs with Lcam
Set a tool length and diameter in the tool offset table, use tool 1 with a length of 0.00 and a diameter of .0625"
On the first G41/G42 in your program add D1, you do not need to do this for every G41/G42 as D1 is global.
e.g.
N5 (File Rib1 )
N10 (Default Mill Post)
N15 (File Posted in Mill Mode)
N20 (Sunday, December 03, 2006)
N25 G90 G80 G40 G91.1
N30 G0 Z1.0000
N35 X1.3309 Y1.9273
N40 Z0.2500
N45 M3
N50 G1 Z-0.1250 F10.00
N55 G42 D1
N60 X1.5034 F15.00
...........
This will make Mach use the tool offset you set in tool 1 for the compensation on the contours.
Try this with the tool just scratching the face of the material, you should be able to measure the size to comfirm all is well.
This is what my Sim gives as the profile.
Graham.