We recently ran a job using institutional RPC 5-knuckle hinges.  In toolbox the door sizes and location look fine.  We have the proper outside and vertical gap reveal. 

During the install though we found that while physically hanging the doors the 1/8” center gap (pair of doors) was basically gone and the doors were rubbing.  This happened as well on single doors but the finished edge reveals basically turned to “0”. 

The only good explanation is variance in the manufacturing of the RPC 5-knuckle hinges.  The best solution in our eyes would be to change the G!Door_Overlay_Institutional variable.  But in doing this we lose the machining for the hinge since it no longer touches the end panel. 

Based on that the only solution for a pair of doors looks to be to change the G!Door_Gap.  I’m not sure if this is the best way to make these adjustments since this is simply a fixed number and not an automatically adjustable variable base don the hinge type.  Also this doesn't solve the issue with a single door or a drawer bank cabinet.