All I can think of is that the template for the centers are off in size.
Re: my avatar quilt pattern: the mistakes in the pattern that I recall were in the mountains. They didn't line up correctly. I was quite perturbed at that time, because she is well known in the quilting world. I wondered, "did she actually MAKE this pattern first before printing it??" Perhaps you should attend the Sister's Quilt Show July 10th and hunt her down!! LOL