I pp'd a king size hunter star quilt last year. It really wasn't horrible. I did end up initially mis-calculating my fabric needs and had to purchase more of the fabric but, oh well. I was able to simply over-size my cut pieces (triangles/rectangles) and had very little waste/block. The waste was not what caused my mis-calculations. I 'designed' the blocks/quilt in EQ5 and just didn't believe I would really need that much fabric. I find EQ - v5 in particular - tends to over-estimate yardage because of how it calculates the fabric cutting.
And granted, the quilt was heavy but just because of it's overall size and the fact that I used W&N cotton batting. I did quilt it on my DSM. Lots of pulling/pushing and a bit of tendonitis as a result but mainly because I was in a rush to get it done.