I had the same problem, and ended up taking the whole thing apart and starting over. It worked the second time, guess I just hadn't done my scant 1/4 inch properly. Love your colours. Hope it works out better on your second attempt.
Sewhappy I think I'm going to start over with different fabric - the extra 1/4" is on the side where I'd have to basically rip apart every seam except for the half-square triangles. I'd rather play around with my machine and start over again. Besides, this way, I can send Joke two blocks instead of one :)