Yes, if it can't be fix then you just have to do your best. I don't normally do any block exchanges either. NOT fun at all when there are blocks that are off.

when easing mismatched seams remember this " lift up your baggy bottoms". What this means is put the longer, baggy bottom, side to the feed dogs. Since the feed dogs run the bottom layer faster than the top layer is dragged along it will add some to automatic easing. As for the "lift up", hold the bottom of the seam you are sewing lift the entire seam length just a bit up off the stitch plate as it goes under the foot. This is an old seamstress trick used to keep the long seams of dresses and pants from growing or shrinking as you sew them. This will add additional easement evenly along the seam line. This can be used even when sewing long strips together by holding and lifting the seams about 10 to 12 inches from the needle area and then adjusting your grip as needed. Give it a try. What have you to lose?

Thanks kellen46. I will tackle the beast this weekend and will combine all the good tips I got. I do appreciate my fellow quilter in cyber world.

How about sashing strips around each block? Then you can square each block to desired (required) size. Works for our groups QOV. Or any group project. Good luck