KCMomTo2 ... I do like your finished block. Quite an interesting design.
An interesting mix of fabrics that work and create some drama to the finished block.
It's really hard for us to diagnose for you, when we can't see them IRL.
I'm somewhat projecting from my own past experiences here ....
Agree with
GingerK that ironing vs. pressing could be part of the problem.
Some others to check ...
Are your seams an accurate 1/4" all the way across?
Sometimes it can become a bit too wide or narrow at the beginning or end, or even in the middle
which then distorts things when all get joined together.
Are all the fabrics 100% cotton? Are they all much the same weight?
I have found that working with lighter cottons can be a challenge to keep all even and accurate.
Sometimes with mixed weights, it can be an even bigger problem.
Are you using Best Press (or similar)?
Sometimes using it before you start cutting can get the fabric to behave better when you cut, stitch, press.
I am a presser, not finger presser .... and keep using BP throughout, if needed. Even on blocks like these.
As
GingerK said, yes they are wonky a bit ... you may be surprised how much of that will disappear once you join them into the big block. Blocking can help .... and the ongoing pressing as you do each stage.
For me ... a pattern like this is a perfect candidate for Paper Piecing!
Looking at your units in post #6, each could be done as one PP unit.
If I want precision and avoid hassles, I have been known to draw it out on graph paper, copy and PP away!
Oh how I love PPing for precise piecing and perfect points!
Good Luck!