I haven't made my own block, so I am not much help on that one specifically, but have printed others from quilters cache...was your test square 1" when you printed the template?
When I go to the "print template" link it opens a window with the template. If I then click on "file" and "print preview" I can found "scale" and click on "custom"...I noticed on mine it said 95% even though I had it set to print at 100%, so changed it to 105 under custom for a different block and the "test square" came out right....I haven't tried with the Friendship Circle yet though...hope this makes sense!