Isn't there an easier way?
 

You would want to cut your squares 6 1/2 by 6 1/2 inches. I don't cut my HSTS until after I have sewn the seams 1/4 inch on both sides of the diagonal. I use an iron to press the diagonal seam on one square and then place it on top and use that to work off my 1/4 inch seam. But you could cut first and deal with the bias seam. That might mean that you pull the square out of shape though.

Once both seams are done, I cut down the middle and press to the dark side. One pressed, I "square up" using a ruler that has a 45 degree angle line and I align that to the diagonal. It helps to have a square ruler and to mark off the total size with painters tape. Just don't forget you will need to have your 1/4 inch seams on the outside.

Don't be frustrated! I think you're probably making it seem more difficult because it's such an important quilt for a special person.

Here's how I would do it:

Cut 14 (6 1/2" wide) strips. From strips, cut 84 6 1/2" squares. Cut them once diagonally to make your half square triangles. Pair them up and sew them together.

Your resulting triangle squares will be just a smidge larger than they are supposed to be. The pattern is using 5 1/2" finished triangle squares, so you need to trim these to 6" square and they'll be ready to use.

Someone else should double check me, but that's how I read it.

Take care, Onalee. I'll keep good thoughts for you and your brother.

Well I guess I should post a link to the pattern on Fons and Porter as the half square triangle doesn't sew to another half square...I'm so sorry after your wonderful explanation luvspaper If you enlarge the picture an then see the black 6 3/8" point of the arrow then is sewn to the other pieces .... I hope that makes sense? https://www.shopfonsandporter.com/product/black-arrow-digital-pattern/shop-quilty/?template=sq

This is basically the same method as leaving the square whole, drawing a diagonal line, sewing on either side of the line, then cutting on the line. In the F&P directions, they just tell you to cut on the line first. There are no extra steps, you just cut first then sew as opposed to sew first then cut.
When you need HST, and you are going to start out with squares that will be cut on the diagonal, you add 7/8" to the finished measurement. So to verify LyndaOH's math, a finished 5 1/2" HST (raw 6") would need a square that is cut at 5 1/2" + 7/8" which equals 6 3/8".
So basically cut the squares at 6 1/2".
Pair up the colors as the pattern tells you & make your HST
Then trim them down to 6". They will finish at 5.5".

I see what you're saying. I'm including an EQ7 diagram of the block to see if I understand how it goes together. The grey area is the black in the pattern.

I think you'll still be fine cutting the strips at 6 1/2" and then cutting them diagonally once. When you sew them to the other half of the block, there will be a litte extra overhang but just align the long center seam with the other half of the block and leave that little extra at each end. You'll then trim your block to the correct size. Let me know if you want me to try and draw a little diagram of how to line of the two halves of the block.

You might also try marking the cutting line on your ruler as someone else suggested, just to see how that works for you. Sounds like less refiguring, etc. Good luck on your quilt and I hope your brother does well with his treatment.

If you want, there is a new Creative Grids ruler that just came out. I bought one at my LQS. It's called the Itty-Bitty Eighths (http://www.creativegridsusa.com/prod...=CGRPRG2&ref=c).