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we have a 8 camera optiTrack system. When we calibrate the cameras we cannot see the capture volume, and the cameras seem further away from the grid then normal this becomes apparent when we try to calibrate a skeleton because the data capture for the t-pose is twice the size then normal. The only way to correct this is too double the height of the heights and shoulders( we shouldnt have to do this ) as the head still screws up when we do.

It sounds like the markers are placed at wrong positions on calibration square. Can you check that the markers are on the end of the square, not at the middle?