I feel so badly for you. I have never had one do me in like that but then again I have not tried a pattern such as that. I have done PP mariners compass which is the same idea. Can't understand why they weren't laying flat for you. I wonder if there was a problem with the paper pattern pieces. I have heard that photocopies of PP patterns can ever so slightly change the size of some pattern pieces.
If it is not too late, you should consider offering it up here on the board for cost of postage. Maybe someone else can have better luck with the blocks you have completed so far or make it work somehow or recut them up into crumb blocks. Seems such a waste to throw away what you have done.