I also had the same problem and decided my quilt will not be accurate and still sewed the borders on without the stars lining up at the corners. Only one corner gave me trouble. I'm not sure what the problem was or is, but decided it wasn't worth worrying about.
Shawn, Haven't a clue, especially without seeing it, but it sounds intriguing. It's what makes quilting so INTERESTING--these odd little mysteries. I would guess it has something to do with the seam allowances not being quite right for starters and a right-left, up-down difference. Hope you succeed in solving it. Cheers, Betty Jo
"Neglect not the gift that is within you..." -1 Timothy 4:14
Okay, I have a bit of a mystery that I cannot figure out. I put the star borders on the two sides and the bottom. Everything fit just fine, the star blocks lined up at the corners, etc. When I went to put the top border on, however, the corners of the star blocks on the top border that are supposed to line up with the corners of the star blocks on the side borders are 1/4" to the right of where they're supposed to be - and thus don't line up. The border itself fits exactly, but the blocks are somehow shifted over ??? If I lay out the border with those star block corners lining up, then I have 1/4" extra at one end and am 1/4" short at the other. I could add a little at the short end to make up the difference, but then I lose the seam allowance at the other end. As I said, I cannot figure out what I did. The rest all went together so well! Any thoughts or suggestions?