Actually Grann of 6 is right - I am easing the triangle insets into the big star. So I marked my 1/4" seam allowances on the insets and the big star and then put a pin into where the seam allowances intersect on both pieces. Its weird - they match fine, but again I end up with fullness in the big star. CK - thanks for the advise on NOT washing the piece first - I ususally don't but I thought maybe it would help in this instance. I wil also try starching the pieces, and definitely quilt the thing into submission! I am thinking about doing FMQ by putting in the Pledge of Allegiance as the quilt pattern - maybe people will be so interested in reading it that they won't see the flaws! :-)