After much measuring and head scratching I figured out I had assumed the tape on my step drill was at 5/8" but it was actually at 9/16. That is why the hole was too small. Retaped the drill and opened the hole to proper size, then edge finished with 220 and 400 grit. Frame fits well now.
Began prep for next cuts with cutting back the protective plastic and re-taping the edge.
