I think it looks amazing! I'd go with it the way it is.

What a great block! It will be perfect.

Great job Linda! If it bugs you then change it.

What you could do is 'needle turn" the sides in a little and stabilize with pins til you stitch it the way you want but blacksmiths rarely start out with a perfect piece. That's why they forge it to their liking or as close as they can get it.

Anxious to see when finished.

I think the applique you've created is fantastic! It doesn't look out of round at all to me. What an awesome idea!

That's going to be a beautiful quilt made especially for your friend. I really like the design. I say leave the circle alone. I like quilts that are not perfect as it truly shows they are homemade. I think sometimes a quilt can be so "perfect" that it's hard to tell if it is really handmade. Besides, once it's quilted & washed you will never see if it's out of round or not. I can't wait to see the finished results.

I think it looks great as it is and also agree that once it's quilted, you won't notice it. But not only that, I think being a bit out of round contributes to a hand-wrought iron type of appearance, so I don't think I'd do anything to change it.

How big is that square?

I had to stare to see what you were referring to so let it go. Absolutely brilliant work and as a wall quilt I would think he'd love it along with anyone who sees it. Also love your definition of UFOs, they do multiply.

I think it looks great. I would leave it as is.