I'm with you all the way on this one! My current EFP (just coined that one) Extraordinarily Frustrating Project... is a log cabin too. I have different problems with mine, but the frustration level is the same. I had mine stitched together (as in thought it was nearly ready to sandwich) and discovered that not all the blocks were the same size and were not laying flat either...BIG OOPS! Back to the seam ripper for me. Good luck on finishing it the way you want it!