Without seeing your blocks, it's impossible to tell for sure. The fact that you tried so hard leads me to believe that the issue is pressing. During assembly or final. check for folds pressed at the seams. The wonky statement says to me you ironed. When I run into a challenge like that I have a pressing board that i drew square sizes on with pigma pen. I will pin a block to the correct size and spray back with starch(before pinning) and press the front. Often all that is needed is to tell the block what is needed from it LOL