Actually, the worse the meshes line up (vertex/edge-wise) the more likely they are to get valid matches .  The current problem seems to be narrowed down to edges - whereas yesterday's version still had problems with verts.  I'll need to take a fresh look at the edge problem when I get a chance.

The bounding box enlargement simply adds/subracts a passed in value from the min/max box values (it's the code you had in there earlier).  You only have to worry about translating it too/from the center if you are using scaling (multiplication).

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