I have a story very similar to AceT's. Over 230 on boards, senior AOA, honors in Surgery clerkship, no med school research, and went to a lesser known med school. Was basically told by my home program, on away rotations, and at interviews that I should have no problem getting interviews and/or matching.
However, Dec. 1 rolled around, and I had a grand total of 7 interviews (out of 30 apps). I spent the next four months incredibly frustrated at the whole process, wondering what went wrong, and stressing about the millions of little things I could have done differently in the application process. Let me tell you, that is something I never want to experience again. Luckily, the 500lb gorilla was lifted from my back on match day, and I matched at my third choice and am happy to be here.
I guess the point is, grades and board scores are great, but no guarantee. I still have no idea why I "fell through the cracks." Maybe I should have applied more broadly and to some community programs (all my apps were to big academic programs). I'm still baffled as to how the whole process works. It seemed to me that 90% of the people who interviewed me were seeing my application for the first time at the interview. So I'm not sure how the decision to interview or not interview someone is made. My gut feeling is that some (but fewer and fewer) programs use board scores and AOA as a cut off, but that more and more are relying on letters and who wrote them. I was told as much by a chief resident at one interview. Away rotations are also key (I matched at a place where I did one).
I guess the point (if there is one), is that matching in Ortho can be a maddening process and it's important to stay grounded. I must say, all the stress was worth it when I could finally say on match day that I was going to be an Orthopaedic Surgeon instead of saying I hoped to be one.