Hi Mrspat and welcome to the board. Are you sure that you cut all your blocks the correct size?? Sometimes I screw up and THINK I have measured correctly and I did not. 4 3" blocks sewn together with a 1/4" seam allowance into a 4-patch should then measure 5 1/2" square (5" finished). Your numbers are correct--just go back and remeasure the blocks you cut.