Nobody has mentioned the quilter's "scant" 1/4 inch. I find that most patterns really mean to use a scant 1/4 inch seam. This measurement takes into account the needle size and thread width of your particular set up. I have learned that using my 1/4 foot but sewing a slightly less 1/4 inch seam works best for me. By slightly less, I mean maybe a thread or couple of thread widths less than 1/4 inch. If you measure your finished size, I think you might be happier. I have never used Bonnie Hunter's tool, but I have thought about purchasing one just to have when changing machines. Try sewing slightly less, a "scant" measurement and see if this helps. Hope it does!