Cut outs not working consistently

I set up a configuration with a cut-out picture and it looks great, and I save the PDF.
Then the next day I tweak the front matter PDF and rebuilt the whole book, and boom the cut-out pictures is all messed up and I can't get it back.

Here is yesterdays PDF:

Here is todays PDF (without changing anything in any of the tabs):

Any clue as to:

1. Why it changed from one day to the next without me doing anything but rebuilding the PDF (I changed the attached Front Matter PDF is all I did, but that didn't change any settings in the configuration.)
2. How can I get it back. Now it ignores most of my setting tweaks for this picture. The original picture format above was set to 50% outside with a +3 line setting. That is the same setting of the second PDF, and in order to get it to even sit on the page I have to reduce it down to 25% but even then the line offset is being ignored.

NOTE: this is the same configuration as uploaded in #782

Start with the configuration referenced in issue #782 and compare the two supplied PDFs, including the front matter PDF change and the cut-out settings. Investigate why rebuilding changes the picture placement or ignores the 50% outside and +3 line settings. Done means reproducing the difference and documenting or correcting the cause so the cut-out remains consistent.