Thanks all. I haven't had this happen to me before and I did it like I always have...make a strip a little longer...lay right side to quilt and feed them through the machine, trim to square after. I'm thinking that there just happens to be more "give" in the particular piece (afterall, it was Christmas day :lol: ) and it ruffled - just on the outside, the sewn seam looked perfect..duh...I guess I've been lucky in the past with my borders.
I did not cut it running with the selvage and I think that is the problem. I'm gonna try to "fix" it though before I cut a new border.