hi, the problem likely was that you simply doubled the size of the block. Instead, you have to subtract the seam allowances, then double, then re-add the seam allowances, then cut. For example, if you were to cut 3" blocks and want to double...3 less 1/2 inch leaves you with a 2-1/2" finished block. Double to 5" and add back the seam allowance, so 5-1/2" to be cut. That should work well.