The pattern is for 84"x84", which is too small for a queen bed IMHO. What size do you want it to be? As you've already discovered, changing the size for this quilt will be much harder than usual. If hubby remembered the seam allowance subtraction requirement, I think I would just go with his calculations, measuring as closely as possible to the 1/32nd inch. With each unit that you assemble, check against what hubby calculates that unit should measure. I also have the pattern, and I also would like to make it smaller, but probably as a wall hanging rather than a throw. That is if I ever get around to it...