I have done this also and just reallylike how it has turned out! It's my own fabric store in my sewing room and it's so pretty to look at. I had my local plastic shop cut mine (only because I wanted them now!) and he charged me .25cents a piece. It was well worth it so I picked up 96 more.
I have seen Dunster's log cabin in person! It is absolutely stunning! The OR/WA quilters get together every other month and she brought it to the gathering.
To make them tight I wrap my boards on my bed or in my hall way. The force of the bedspread or the rug helps me to keep it tighter. I also when wrapping push the board to me using my fingertips on the side that is farthest from me. Hope that makes sense. I also secure using a bolt buddy. I'm trying not to wrap anything bigger than 5 yards on my little bolts. They seem to get bulky and loose and I'm also very limited to shelf space right now.