Take your rotary cutter to you local quilt shop and ask someone to look at it. I bet you put it together wrong. Or, spend a few bucks and buy a new one. You said it's been a while since you've sewed. Maybe your rotary cutter is out of date and a new one is just what you need. A new one with a new blade will make all the difference in the world. And it will be less than $20. Go for it! Also, google "how to put a rotary cutter together" and see what pops up. Someone had a site on here recently.