Hi there Yetti,
Boiling down to final volume can be a problem especially with beers that are hop-driven. A better policy is to use less water and top up a little at the end of the brew. This makes things easy.
Another problem with boiling down is that you never really get a good handle on what is going on. If you are spending more time boiling down, how will you get to know your average evaporation rate for example?
One more thing is that when you are boiling down, you are lowering your volume but increasing your gravity. It is important to know, at the end of the day, if you are ending up with too much beer at the right gravity or the right volume at the right gravity or too little beer at too low a gravity or one of the many variations of these.
So, use a bit less water and let your brew ride with no adjustments until it reaches the fermentor. Take a few gravity and volume readings (beginning and end of boil and into the fermentor) and if needs be, top your fermentor up a little.
Can you let me know what software you are using of how you are working out what volume of water to use? If possible, post a recipe file up, spreadsheets and/or a recipe report as there will very likely be a problem happening there as well. The PS below may also help.
PP
P.S. The BIABacus is a bit daunting especially as there is no good help written for it atm. The trick until there is help is learning what to look at first. Here's a version where I have blanked out a lot of stuff so that you are forced to just concentrate on volume figures, total grain weight and gravity.
Volume, Grain Weight and OG Play-Around.xls
There is an interplay between these three very basic things that is not dealt with by any other commercial software besides the BIABacus. Change the numbers in Section B to suit your equipment and the OG in Section C to suit your recipe. After you have done this, the main volume number to look at it is Total Water Needed.
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