Ah. Good thoughts. Re interfacing: I was considering just fusing it around the edges combined with assembly by serger to control stretch. Just not sure about sagging/ bagging of the block centers with use.
I never thought about pouncing. The more I reflect, this is the ticket. Thank you. This woulid even allow me to custom size/ enlarge the design. Believe me that I will not be doing anything tight. This is not the place for 1" or stipple.
Re: declining the job. I have tried. Even quoted 3x my normal rate because I knew this would be trouble. Client is paying, so I am quilting. Perhaps I work out all the details, write a book, amd become rich and famous!
Wishful thinking on my part.