Michael,
Your post is simply antithetical to my process. I'm like you: Pin the seam, sew the seam, "set the seam" by pressing (not ironing!), and, finally, press the seam towards the dark. Repeat this a million times until your quilt top is done. And, oh, by the way, I don't use steam, but I will use Best Press, which is absolutely remarkable.
If I am following the logic, Kaye is saying if you cut correctly, and sew a 1/4" seam, everything will turn out correctly. Perhaps hew logic is all that "handling" of the fabric contributes to distortion. Am I correct? Actually, it makes sense.
I am about to embark on another project. I will try not pressing. This will be OH, SO DIFFICULT not to press, but I will try it. Film at 11!
Janet :)