diff --git a/frontend/src/png/overlay.test.ts b/frontend/src/png/overlay.test.ts
index 9e071be..b38c1f1 100644
--- a/frontend/src/png/overlay.test.ts
+++ b/frontend/src/png/overlay.test.ts
@@ -385,35 +385,55 @@ test('buildOverlayPlan: length axial span = tip span; inventory y stays within w
     `length bottom y=${lenMaxY.toFixed(1)} must not extend past wood AABB maxY=${mMaxY.toFixed(1)}`,
   );
 
-  // Measured axial span equals mask tip-to-tip (dim line parallel beside wood)
+  // Length endpoints = robust tip pixels + common screen offset → tip-to-tip span
   const { start: aa, end: bb } = axisEndpoints(bbox);
   const ex = bb[0] - aa[0], ey = bb[1] - aa[1], elen = Math.hypot(ex, ey) || 1;
   const ux = ex / elen, uy = ey / elen;
   const cx = bbox.corners.reduce((s, c) => s + c[0], 0) / 4;
   const cy = bbox.corners.reduce((s, c) => s + c[1], 0) / 4;
-  const cProj = cx * ux + cy * uy;
-  let tipMin = Infinity, tipMax = -Infinity;
+  const projs: number[] = [];
+  for (let y = 0; y < H; y++) {
+    for (let x = 0; x < W; x++) {
+      if (!bitset[y * W + x]) continue;
+      projs.push(x * ux + y * uy);
+    }
+  }
+  projs.sort((p, q) => p - q);
+  const lo = Math.min(Math.floor(projs.length * 0.002), projs.length - 1);
+  const hi = Math.max(Math.floor(projs.length * 0.998), lo);
+  const tipMin = projs[lo];
+  const tipMax = projs[hi];
+  const stationTol = Math.max(1.5, (tipMax - tipMin) * 0.001);
+  let tipMinPt: [number, number] = [0, 0];
+  let tipMaxPt: [number, number] = [0, 0];
+  let bestStart = Infinity, bestEnd = Infinity;
   for (let y = 0; y < H; y++) {
     for (let x = 0; x < W; x++) {
       if (!bitset[y * W + x]) continue;
       const p = x * ux + y * uy;
-      if (p < tipMin) tipMin = p;
-      if (p > tipMax) tipMax = p;
+      const across = Math.abs((x - cx) * -uy + (y - cy) * ux);
+      if (Math.abs(p - tipMin) <= stationTol && across < bestStart) {
+        bestStart = across;
+        tipMinPt = [x, y];
+      }
+      if (Math.abs(p - tipMax) <= stationTol && across < bestEnd) {
+        bestEnd = across;
+        tipMaxPt = [x, y];
+      }
     }
   }
-  const tipStart: [number, number] = [cx + ux * (tipMin - cProj), cy + uy * (tipMin - cProj)];
-  const tipEnd: [number, number] = [cx + ux * (tipMax - cProj), cy + uy * (tipMax - cProj)];
-  const oriented = pickBottomTowardTop(tipStart, tipEnd);
-  const mapBottom = inv.mapToInventory(oriented.bottom[0], oriented.bottom[1]);
-  const mapTop = inv.mapToInventory(oriented.top[0], oriented.top[1]);
-  const proj = (p: [number, number], o: [number, number]) =>
-    (p[0] - o[0]) * oriented.ux + (p[1] - o[1]) * oriented.uy;
-  const tipSpan = Math.abs(proj(mapTop, mapBottom));
-  const lenSpan = Math.abs(proj(plan.length.b, plan.length.a));
+  const tipOr = pickBottomTowardTop(tipMinPt, tipMaxPt);
+  const mapTipBot = inv.mapToInventory(tipOr.bottom[0], tipOr.bottom[1]);
+  const mapTipTop = inv.mapToInventory(tipOr.top[0], tipOr.top[1]);
+  const tipEuclid = Math.hypot(mapTipTop[0] - mapTipBot[0], mapTipTop[1] - mapTipBot[1]);
+  const lenEuclid = Math.hypot(plan.length.b[0] - plan.length.a[0], plan.length.b[1] - plan.length.a[1]);
   assert.ok(
-    Math.abs(lenSpan - tipSpan) <= 2,
-    `length axial span ${lenSpan.toFixed(1)} must equal tip span ${tipSpan.toFixed(1)}`,
+    Math.abs(lenEuclid - tipEuclid) <= 2,
+    `length span ${lenEuclid.toFixed(1)} must equal tip-to-tip ${tipEuclid.toFixed(1)}`,
   );
+  // Arrowhead stations share tip screen-y (vertical-ish fixture)
+  assert.ok(Math.abs(plan.length.a[1] - mapTipBot[1]) <= 1.5 || Math.abs(plan.length.a[1] - mapTipTop[1]) <= 1.5);
+  assert.ok(Math.abs(plan.length.b[1] - mapTipBot[1]) <= 1.5 || Math.abs(plan.length.b[1] - mapTipTop[1]) <= 1.5);
 
   // Length stays axis-right of wood (clearance to the right in inventory x for this fixture)
   const lenMidX = (plan.length.a[0] + plan.length.b[0]) / 2;
diff --git a/frontend/src/png/overlay.ts b/frontend/src/png/overlay.ts
index 73eb341..6841fd8 100644
--- a/frontend/src/png/overlay.ts
+++ b/frontend/src/png/overlay.ts
@@ -83,7 +83,16 @@ function maskAxisSegment(
   w: number,
   h: number,
   bbox: BBox,
-): { start: [number, number]; end: [number, number]; ux: number; uy: number; span: number } {
+): {
+  start: [number, number];
+  end: [number, number];
+  /** Actual mask pixels achieving min/max axial projection (wood tips). */
+  tipStart: [number, number];
+  tipEnd: [number, number];
+  ux: number;
+  uy: number;
+  span: number;
+} {
   const { start: a, end: b } = axisEndpoints(bbox);
   const ex = b[0] - a[0];
   const ey = b[1] - a[1];
@@ -93,21 +102,50 @@ function maskAxisSegment(
   const cx = (bbox.corners[0][0] + bbox.corners[1][0] + bbox.corners[2][0] + bbox.corners[3][0]) / 4;
   const cy = (bbox.corners[0][1] + bbox.corners[1][1] + bbox.corners[2][1] + bbox.corners[3][1]) / 4;
   const cProj = cx * ux + cy * uy;
-  let minP = Infinity;
-  let maxP = -Infinity;
+  // Collect axial projections; absolute min/max tip pixels can be mask specks
+  // past the visible wood footprint (Ty UAT #69). Use robust percentiles and
+  // pick tip pixels near the centerline at those stations.
+  const projs: number[] = [];
+  for (let y = 0; y < h; y++) {
+    const row = y * w;
+    for (let x = 0; x < w; x++) {
+      if (!bitset[row + x]) continue;
+      projs.push(x * ux + y * uy);
+    }
+  }
+  if (projs.length === 0) return { start: a, end: b, tipStart: a, tipEnd: b, ux, uy, span: 0 };
+  projs.sort((p, q) => p - q);
+  const lo = Math.min(Math.floor(projs.length * 0.002), projs.length - 1);
+  const hi = Math.max(Math.floor(projs.length * 0.998), lo);
+  const minP = projs[lo];
+  const maxP = projs[hi];
+  // Tip pixel at each robust station: closest to the axis centerline
+  let tipStart: [number, number] = a;
+  let tipEnd: [number, number] = b;
+  let bestStart = Infinity;
+  let bestEnd = Infinity;
+  const stationTol = Math.max(1.5, (maxP - minP) * 0.001);
   for (let y = 0; y < h; y++) {
     const row = y * w;
     for (let x = 0; x < w; x++) {
       if (!bitset[row + x]) continue;
       const p = x * ux + y * uy;
-      if (p < minP) minP = p;
-      if (p > maxP) maxP = p;
+      const across = Math.abs((x - cx) * -uy + (y - cy) * ux); // |(p - c) cross u| via r
+      if (Math.abs(p - minP) <= stationTol && across < bestStart) {
+        bestStart = across;
+        tipStart = [x, y];
+      }
+      if (Math.abs(p - maxP) <= stationTol && across < bestEnd) {
+        bestEnd = across;
+        tipEnd = [x, y];
+      }
     }
   }
-  if (maxP < minP) return { start: a, end: b, ux, uy, span: 0 };
   return {
     start: [cx + ux * (minP - cProj), cy + uy * (minP - cProj)],
     end: [cx + ux * (maxP - cProj), cy + uy * (maxP - cProj)],
+    tipStart,
+    tipEnd,
     ux,
     uy,
     span: maxP - minP,
@@ -174,7 +212,8 @@ export function buildOverlayPlan(input: OverlayPlanInput): OverlayPlan {
     const leftSrc: [number, number] = [ox + rx * extent.minP, oy + ry * extent.minP];
     const rightSrc: [number, number] = [ox + rx * extent.maxP, oy + ry * extent.maxP];
     // Width number sits axis-left outside the slab (past left tip).
-    const labelOff = extent.minP - pad - scale * 0.4;
+    // Extra clearance so glyph box (textAlign grows away from wood) stays off footprint.
+    const labelOff = extent.minP - pad - scale * 0.4 - Math.max(22, Math.round(scale * 1.0)) * 0.35;
     const labelSrcW: [number, number] = [ox + rx * labelOff, oy + ry * labelOff];
     const widthIn = (extent.maxP - extent.minP + 1) / scale;
     widths.push({
@@ -198,10 +237,31 @@ export function buildOverlayPlan(input: OverlayPlanInput): OverlayPlan {
     if (extent && extent.maxP > maxRight) maxRight = extent.maxP;
   }
   const outward = maxRight + pad;
-  const aSrc: [number, number] = [bottom[0] + rx * outward, bottom[1] + ry * outward];
-  const bSrc: [number, number] = [top[0] + rx * outward, top[1] + ry * outward];
+  // Tip pixels = wood ends. Translate them by a single screen-axis offset so the
+  // dim line stays || tip-to-tip (measured span = wood tip-to-tip) and arrowheads
+  // share tip y (vertical-ish) / tip x (horizontal-ish) — no past-footprint
+  // overshoot from (rx,ry)*outward (#69). Clearance magnitude matches classic
+  // axis-right mid (centerline + r*outward).
+  const tipOriented = pickBottomTowardTop(seg.tipStart, seg.tipEnd);
+  const aClassic: [number, number] = [bottom[0] + rx * outward, bottom[1] + ry * outward];
+  const bClassic: [number, number] = [top[0] + rx * outward, top[1] + ry * outward];
+  const tipMidX = (tipOriented.bottom[0] + tipOriented.top[0]) / 2;
+  const tipMidY = (tipOriented.bottom[1] + tipOriented.top[1]) / 2;
+  const classicMidX = (aClassic[0] + bClassic[0]) / 2;
+  const classicMidY = (aClassic[1] + bClassic[1]) / 2;
+  let aSrc: [number, number];
+  let bSrc: [number, number];
+  if (Math.abs(uy) >= Math.abs(ux)) {
+    const dx = classicMidX - tipMidX;
+    aSrc = [tipOriented.bottom[0] + dx, tipOriented.bottom[1]];
+    bSrc = [tipOriented.top[0] + dx, tipOriented.top[1]];
+  } else {
+    const dy = classicMidY - tipMidY;
+    aSrc = [tipOriented.bottom[0], tipOriented.bottom[1] + dy];
+    bSrc = [tipOriented.top[0], tipOriented.top[1] + dy];
+  }
   const midSrc: [number, number] = [(aSrc[0] + bSrc[0]) / 2, (aSrc[1] + bSrc[1]) / 2];
-  // Nudge label further outward a bit
+  // Nudge label further outward a bit (axis-right of dim line)
   const labelSrc: [number, number] = [midSrc[0] + rx * (scale * 0.4), midSrc[1] + ry * (scale * 0.4)];
 
   const fontPx = Math.max(22, Math.round(scale * 1.0));
@@ -264,11 +324,15 @@ export function drawOverlayPlan(
 
   // Length
   arrow(plan.length.a, plan.length.b);
+  ctx.textAlign = 'center';
   ctx.fillText(plan.length.label, plan.length.labelAt[0], plan.length.labelAt[1]);
 
-  // Widths
+  // Widths — grow text away from wood (labelAt is axis-left of left tip)
   for (const w of plan.widths) {
     arrow(w.left, w.right);
+    // labelAt is on the axis-left side of the station; align so glyphs extend further out
+    const towardLeft = w.labelAt[0] <= w.center[0];
+    ctx.textAlign = towardLeft ? 'right' : 'left';
     ctx.fillText(w.label, w.labelAt[0], w.labelAt[1]);
   }