[Captain Ahab Jr]

With FIA car shape rules you push the limits to the max

If it is a trimmed/machined edge of a carbon part like the floor the limits to the FIA rules is much tighter than say moulded surfaces as it's easy to shave a smidge off at the track before running by sanding away 1mm etc

Reading what James has said, team did scans with floor off the car and on the car both at the factory and Thurs. at the track. Sounds to me like they did the right level of inspection as just not enough time to scan the car before every track running

Just guessing but I'm thinking the problem will be a combination of how precisely the floor is located on the car ie stack up of tolerances and maybe the 1st few on track heat cycles from the engine caused the moulded floor shape to distort slightly