I have been reading the posts and noticed that when some of you have printed out your patterns, they end up being about 15 inches. If you have made your block a bit smaller, don't worry - as long as you can cut the block to a full 16-1/2 inches square (unfinished size) when you have finished your applique.
As for the patterns not printing out correctly, I can offer one solution that may solve the problem for most of you. I suspect that when you go to print the blocks, you may be going directly to "print" and bypassing a print "menu." In the print menu, there is a little pull-down menu for "Page Scaling." You want to make sure that you have selected "None" instead of "fit to printable area" or "shrink to printable area" -- which your computer may automatically select since the margins on the pattern pages are very tight! If the printing is scaled to fit the page, your pattern will print out at about 15 inches instead of the full 16 inches.
I hope this is helpful information for those of you who have had problems with page sizes.