Nanna-up-north without your epic journey I would have never even crossed the street. On the HST I use the 8 to a square method. To get the 8 is easy enough but then I have to square up each one which takes a little bit of time. I have been getting 80 HSTs to each 4" cut (42" fabric). The proof in the pudding will come when it's time to sew the sets to the appliqued squares. I can only hope they come together half as good as yours are. Doing a day of cutting and sewing HSTs now and then gives my fingers a break from all the needle work.
While I have you here I have to ask you something. Did you start with a 9" square and then applique? And if so how hard was it to get them all cut down to 8 1/2" before assembly? With all the stuffed pieces I'm concerned about being able to get a clean squared up cut.