I could not agree more with what you said. Some of BB's decals are not exact, maybe a lot of them. I can only go by what I used. We worked together making some decal sets and I had very little input on final designs. His attitude seems to be close is good enough. He does get official Schwinn approval but apparently that does not translate into accuracy. When I said better I was actually thinking they install and stick better. I had a bunch of Memory Lanes decals fall apart sliding them off or not sticking, lots of silvering. Velocals has the good enough attitude as well but they're not into repro waterslide decals. Vinyl's mostly. No one is making anything I'm thrilled with.
Some times it's tough to tell, especially if you've taken off the old decal and replaced the new. BUT if you're paying attention, as in the case of the OP who wants to 'maybe' apply directly over the old, or in my case, I'd put marker lines where the old was, so I could get it back in the right spot, only to discover the new one was 11-1/6" and the old; 10-1/4. Had I not marked I never would have noticed. whoever made the decals, stretched them in whatever program, Photoshop or whatever, which also made the letters thin, so, in the Ops case whether the same as I replaced or another type where size and or details were so poor, it would never align or cover the old..
Also, once I realized this, I was on a hunt to find original bikes and their decals. then, I also discovered while length was consistent letter thickness on originals, {waterslide}, wasn't Then I realized Schwinn's decals must have been screen printed and it meant potential clogging that can make variances. Regardless, replacement "Approved" >> Practically a whole inch longer is not good.
Sooo,,, all around nice guy, cept fer 1 itsy bitsy 15/16" thing. It hasn't stopped em from being passed off.
Everbody else had that wrong decal too the same sized that Bones claimed he had made from the original, except, after months of searching, VintageSchwinn.com turned up with the right one.