Hi Jane,
For what it's worth and hoping it will help...
When I ordered my Sherpa, I didn't start from scratch on the sizing. At that time (Summer 2011), Thorn had a different sizing system, and I simply transferred my measurements from a bike (several, actually) that fit me perfectly. The Sherpa I received (a 560S with drop handlebars) fit just like my other bikes. The only "adjustment" from Thorn's usual was the inclusion of a large-layback seatpost to get my relationship with the bottom bracket to match my other bikes.
The Nomad sent in replacement was modeled after my Sherpa's measurements. It not as ideal a fit frame-wise with drop 'bars due to different geometry (590M with longer top tube than the 560S Sherpa's), but with some juggling of the stem's reach (shorter) and brake lever placement on the handlebars (higher and closer), the effective fit is the same as the Sherpa and matches my other bikes so it feels the same when on it. The Nomad also required the large-layback seatpost to put me where I needed to be over the BB with my preferred Brooks B.17 saddle, which has short rails; the seatpost setback makes up for that.
I do know the Sherpa Mk3 line was redesigned after my Mk2 was produced, and the new frame geometry would have resulted in a less-ideal basic fit for me. I do think it could have been adapted with adjustments in stem length (reach).
All of this is by way of saying I found Thorn's sizing to be excellent in duplicating the fit of a bike I already owned and liked and fit me properly. I don't know how it would have been if I had started from scratch.
Thorn have recommended a 500L (I am 5'4" with standover 77.5cm). This has a top tube that is longer than that on my husband's bike (he is 5'10"). Does this mean Thorn are recommending a bike too big for me or is my husband's bike too small?!...Obviously my husband's Marin Novato and a Sherpa have different geometry.
Without seeing the bikes or knowing if one or both have dropped or straight handlebars, I would guess the difference is due to geometry and intended use and preferred position.
Jane...do you have the opportunity to try some friends' bikes or perhaps take a test ride of a local bike so you can get an idea how a different frame/bike might feel or fit? Actually getting on a bike can make a tremendous difference, and even a cm one way or another on handlebar reach or height can transform a bike from good to bad or vice versa.
I hope something in this helps.
Best,
Dan.