Lesley & Patti - thanks for the size tips, I will try them.
I use a tighter stitch on the PP too, it does help, but if I make the stitch any smaller, I would not be able to rip out a seam if I need too, as once in a while I will not use a patch large enough...but I can say this, I have learned a lot from working on this quilt already! Thank you Jane! :)