Did you measure the borders before reattaching. Sounds like they might not be correct. Make sure the two side borders are the same. Same with ends. Take the two sides measure down the center of the quilt and cut to the measurement if necessary. Sewvon and the measure the width. Etc. you may already know this. And then ease in if necessary. There is indication that something is not right when you say the border is 1+ inches longer than the side of the quilt.