You guys are all awesome!!
@Steve_Mayze nailed it. The solder mask clearance value was .007…" on my new boards and 0 on my old boards. I am using KiCAD 4.0.6 on Windows. What I find very interesting is that 0.007874015748" = exactly 0.2mm… I don’t remember setting that value and it is really odd that Steve, @ALeggeUp, and I have the exact same value.
KiCAD issue?..
I have made the following changes, thanks to @AlanFord, on the 4 boards I had issues with. I will re-order one of them and see how things look.
I didn’t notice any visible changes in KiCAD when I redrew the pours/planes (keyboard b). Is that expected?
OLD Pads Mask Clearance
Solder Mask Clearance 0.007874015748" = 0.2mm
Solder Mask Min Width 0
NEW
Solder Mask Clearance 0.002" = 0.0508mm
Solder Mask Min Width 0.004" = 0.1016mm
All of my older boards that worked fine
Solder Mask Clearance 0
Solder Mask Min Width 0
Do I need to adjust my pours from .005" clearance and .01" min width?
I created a new project from scratch and see the same default. It looks like this may be the issue we have run into.
It may help to get the default changed if you click the link on that page to tell them the issue is affecting you. I added a comment and clicked the “it is affecting me” link