I think you're over-estimating the Boveda for one. I thought it was, and tend to not go above myself, 25 cigars to each Boveda pack. I try to keep it closer to 15 per pack, with exception of short/thin ring gauges. Even then, I don't go over 25 per container.

As mentioned, both are reading high..though I believe your hygrometer is off(possibly due to time it may have been exposed to outside air). I highly doubt they would be cracking at 74%. I would try getting the temp a tad lower, but even then if the Boveda aren't drying out, they are working as intended and should be keeping things in the appropriate range for the most part.

What is your normal method of cutting? What type of cigars? ..if you continue having the problem, try to put the cap in your mouth for a minute before you cut. Get it a little wet, so that the wrapper is more pliable. Cut it without wiping/drying it, to give a little more flexibility. It may help keep from cracking. Also, check your cutter.. How old is it, is it still nicely sharp? Clean edge, no knicks? Those could cause problems in the end, too.