I think it looks good the way you're doing it. It's supposed to look scrappy and it'll look like a "guys" quilt with the plaids.
Just a thought: If you have a few different plaids you could use one plaid on all four sides of one block, a diff on the next block and so on. When you put the quilt together you'd just make sure you didn't put the same borders next to each other and I think it would be a great looking scrappy quilt.
I know it's frusterating when you can't seem to get the look you want, most of us know that feeling. Whatever you decide and however it turns out, your dh will love it because it was made by you for him.