Update: I appreciate all the tips. Unfortunately, I have cut all the pieces so some tips are obsolete at this point. However, today I took a deep breath and worked on #4 block.....I carefully pinned all the pieces AFTER I mareked the end point with a 1/4" on each seem to converge at the middle point. I then carefully matched up all the side seams to make sure they all lined up. I then sewed CAREFULLY and pressed CAREFULLY. On the final seam between the two halves, I started at the center and sewed out to the end and then began again at the center and went the other direction. I pressed the final seam open and (happy dance).....it lays FLATTER; notice I said flatter as there is still some play in the fabric, but I am now convinced that this situation is one of those we have to live with! Thanks to all who offered help. This is the greatest site ever!!!