Jerry---
    I can not comment on the RS274-X format since I don't have hands-on with
  the work anymore, however I would suggest that you revise your process in 
  dealing with your bare board suppliers. This doesn't make your job any 
  easier, but it will help to ensure that your end product is what you 
  expected, which is the goal. We generated a gerber file, YES YES YES-with 
  aperature and wheel definition, we maintain a standard aperture list for 
  ALL designs (SMT/thru-hold), and send it to our laser photoplotter. We then 
  verify that the phototooling represents the design and then release those 
  files along with a set of phototooling to the board fabricature. The vendor,
  per the purchase order, has the responsibility to ensure compliance between
  the phototooling that he generates and the supplied phototooling. We did 
  experiece some start up problems with some of the first complex SMD designs,
  but that was problems with our library definition. However, the supplier did
  catch the discripencies and the finished product was correct. The use of a 
  standard aperature list and vendor responsibility for phototooling compliance
  has ensured a steady supply good product from our bare board supplier. Hope 
  this was not too windy and of some help. If you would like to discuss this
  further, please call. 
                                       Have a good day--
                                           Bob Vanech
                                           (203) 852-4810