[QUOTE=pumpkinpatchquilter;6837309]It sounds a lot like maybe the sashing and/borders are larger than the blocks.
I would agree with the above statement. When measuring for your borders, you need to measure through the center of the quilt in both directions. This has happened to me before...and, yes, I had pleats in my borders. Kind of a bummer when one has spent all the time and money to create a quilt.