I'm sorry you had problems. It might not be just your quarter inch foot. It could be the thread you are using too. If the thread is on the thicker side, you need to be one or two threads shy of the one-quarter inch. This would be enough to make the difference you mentioned.
Using a thinner thread you would only need to be shy maybe one thread width. Quilt patterns call this using a scant quarter inch.
A lot of patterns and pre cut kits are designed using computer programs that do not allow for the thread difference.