Gail - the only thing I don't understand is why it is happening with the DJ only and not with other quilts??? By now I am familiar with my own sewing habits and know exactly what part of my machine the fabric pieces I am sewing together needs to line up with to make that 1/4" seam. but it is consistent with all projects - have you changed the weight of your thread, size of needle, had your machine serviced?? If you are consistently producing blocks that are a little small, I would adjust cutting method and/or sewing line.. when I cut, I line up ruler 'on the' fabric rather than 'against' it - i.e. to cut 2" strip, I make sure the cut edge of fabric is under the 2" line - that way I have a few extra threads to make sure I can take a full 1/4" seam [or cpl threads more] without losing the full pattern. You can also make sure your machine's 1/4" line - or - the edge of your 1/4" foot ends past your fabric slightly.
hope this helps!





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