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Even using that calculator its trial and error I used it when I ordered my line originally and the were far too short weather that is because of my tap position or other factors I don't know all I know is that 10 PSI @5C gives me 2.3 volumes and it pulls perfect pints 95% of the time.
Also http://beersmith.com/blog/2011/07/14/keg-line-length-balancing-the-...
Should have asked earlier are you using a standard tap or one with the flow restrictor adjustment on it?
Have you tried using a picnic tap in place of the proper tap you have on there, to see whether that makes any difference? Might just help eliminate another possibility of where the issue is in the system.
Yeah second that, picnic taps with that black hose which has a tiny inner diameter are really good for checking such things. You don't need any length of hose before the tap as the tight inner dimension provides enough line resistance. I've got 2 and they're simplistically awesome.
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