Ok, simple thing:
I have an rendered image and want to mask out an area for whatever purpose. So i render a mattepass accordingly, using the very same geometry an put black or white constant shaders on, nothing special.

But then I decide to mask out the other part of the image by inverting the mask and -oops- I discover the white area is significantly smaller than the orignial colour area.

No matter what I do mental ray seems to render white areas smaller than the black ones. If I don´t invert the mask, but use it, for example, for masking a colour correction, it looks like this:

Or if I just want to comp my cut out image over the exact same are area in another pass, it looks like this:

I´ve been rendering and using mattepasses all the time, and never had this problem. It looks like the fringes are way more than one pixel, so it can´t be antialiasing only. It´s almost the same in maya, only the fringes seem an bit narrower rendered in maya. The Mask port uses red, because I need to use luma instead of alpha for masking.
All images are rendered with standard sampling, 1, 3, 0,036, triangle filter, 3px as 8 bit tiff. Switching colorprofiles doesn´t do anything either.
Using matte shrink or expand filters is not a solution, since they tend to soften the matte and make it even more inaccurate.
I have no idea at the moment why this happens and why it happens now. Has anyone else this problem? Mattes are quite useless at the moment for me, and that´s a huge problem.
Achim
Edit: It´s SI 2012 SP1 and Maya 2012 Hotfix2 (64 bitch both) by the way.
