the pattern is cleopatra's fan - a freebie on the kaufmann website. i hand pieced the block and added the border by machine so the puckering is a result of different thread tensions. i figure once quilted and washed it will be more than fine.
i think klo's idea about what happened is true. the block is pieced in halves and then joined through the centre like that. none of the four are identical, but as setting blocks they'll be far enough apart that they'll seem identical, mostly.
handbasting makes a lot of sense in this context, as do bear's ideas about pin setting. and the rest ofyour thoughts too. so appreciated.
thank you so much. this place is a treasure.
aileen