Are your seams pressed in opposite directions so they nest? With smaller patches I find this is important. Also, even though the patches are only 1.5", if I'm having trouble, I pin both the leading and trailing edges. And last but not least, take a minute to double check your seam allowance:
http://www.quiltingboard.com/tutoria...ce-t89997.html
I am planning on spending the afternoon squaring up some 1.5" HST with my blocloc. However, I only have to do a million, not a gazillion
