I'm using the stitch and flip method, with 2.5 inches squares on either side of the 4.5 inch background. I also then am sewing a short distance away from those seams, creating bonus triangles which I have other plans for. I think I've been making that second seam too narrow, thus having too narrow a seam allowance on the FG. Thank you all for your help, information, and links. I'll check them out, as they look promising!

Sorry to hear that's your experience! I haven't had an issue with these and I've been using them with the Elmer's purple glue sticks. I know others have used them with off brand glue sticks and have had trouble.

I used to buy the arlenes glue, until I read on here about using Elmer's school glue. I now refill the arlenes bottles I saved with the Elmer's. Works perfectly. Hit it with an iron to set it, and your ready to sew. The fine tip that comes on the arlenes bottle is great for getting a thin line or a dot of glue in just the right spot.
Hot water and a straight pin keeps the long tip cleaned out and working perfectly for years.