Just wanted to say: It's too hot for hunting bugs, but then I saw, that you don't live in Europe....
If you just want to solve the problem, then there is a rude way:
In TForm1.resize check if the Form has the desired height and width.
If not resize the Form and all the children.
I did that once when the KDE desktop hat strange ideas about the size of the application while restoring a session.
This works but you'll never know what's the reason of this strange behaviour.
Winni