After block #7 I refer to this BOM as the Civil War Torture Kit. The fact that you have to make eight of these is insane!.. LOL. That said here's what I did. I cut the units a little larger and then ONE BY ONE using a ruler with 1/16th marker - trimmed them down. Also, I found if I didn't use the iron but just finger pressed the seams it helped. Good Luck!
P.S. My LQS owner said the October block is even worse >. She's making alternate instructions for her customers.