How easy to forget that some do not know this step. It never crossed my mine that it may not be squared up and that was causing the problem.

Sew your strips together and carefully press so that there all seams are completely pressed, no wrinkles/gathers/puckers.
Measure the width of the sewn strip set several times down the length of the set.
That measurement of the sewn strip set will determine the size of your subcuts. They are often a hair more or less than you thought they would be.

Jan in VA

Thank you everyone.

Jan, why do the instructions say to pre cut the three pieces that will be sewn together the same size?

Because the longer the strip you sew together the more chance there is for distortion in sewing and/or pressing. I have some 30" strips to sew for a Jinny Beyer DA VINCI quilt and know they will need extra care. Thanks for asking your question. The answers reminded me of some thing I need to be aware of for upcoming quilt.

I know you already have your answer, but I wanted to let you know you're not the only one!

I have a set of UFO rail fence quilts that I started 10 years ago. I just picked up the completed strip sets for one of them, and I'm SO glad I measured before I started cross-cutting for my blocks! It seams (haha) that my scant 1/4" wasn't so scant 10 years ago, and my strip sets (full width of fabric) were pretty uneven. I just cut my blocks to be 6-3/8" (the width of my strip sets) instead of 6-1/2" (that they were supposed to be), and when I put the top together, everything was perfect.

I'm hoping that the strips for the other quilt won't be so far off, since the sets aren't finished yet... Will see!

Because they are assuming you have cut the fabric correctly, and your seams are precise. You said your seams were OK, but did you double check using the instructions in this tutorial?

http://www.quiltingboard.com/tutoria...ce-t89997.html

Jan clarifies her previous post:
I wasn't clear that when you measure the sewn strip set in several places, you average those measurements and determine from the average what size to cut ALL your subcuts. There will be some blocks that you will have to 'ease' a bit to fit their adjoining block, but "on average" more of your subcuts blocks will fit together than than if you don't do it this way.

Jan in VA

When you cut the blocks do you measure the width of your strip set, your cuts should equal that size. even if your seam length is off it should be somewhat consistent to each other and if you measure the width you can go off of that. My rail fence was much more accurate this way. Also your cutting of the strips needs to be consistent, if they are all different widths because of inaccurate cutting

I had the same problem. I thought I was crazy! Lied is short don't make any more rail fence quilts. Lol

I absolutely love the Quilting Board. It is the best quilting resource of all times. I have learned so much here and continue to learn something new every day. To me it's better than going to a class. It is a class! My sincere thanks to everyone for your expertise and knowledge that you so willingly share. I love the article on achieving an accurate quarter inch seam and can't wait to try it. You ladies are the best teachers of all!