It could be a rounding issue.
Assuming I'm not missing any errata/rules changes for the patchwork armor, the rules state that you calculate the weight of the armor (rounding up to the nearest half ton) for each location.
So unless I'm mistaken, as soon as you make the design utilizing patchwork armor, you have to recalculate the weight of all that Ferro Fibrous armor as well, and the rounding might be where the other weight is coming in.