One thing I notice from the pattern to the finished block did you print at the correct size? What I am asking is did you check the 1 inch square to see that it is a 1 inch square? If the paper piecing is off then it could set the block off. Also this sounds strange but where do you place your ruler on your fabric. Do you have the edge of the ruler on the fabric so you can see the fabric at the breaks in the ruler spacing? If not that will change the size as well. Also I would try a thinner weight thread like a 60 weight for the paper piecing and regular piecing. It could just make a difference. As well as sewing just touching the outside of the paper piecing line will help as well. Let me know if any of these things helped! Luann in CT