The blocks varied in size from about 11 inches to 12 1/2 inches. In order to use all of the blocks in close to their original size, I decided to make the blocks the center of a square in a square and then trim the new blocks to the same size. This was my process.
With the largest blocks at 12 1/2 inches, set on point, the with of the new block at a minimum would be 17.67 inches (remember the pathagaream theorem?). So I needed to cut setting trianges large enough to cut down. I cut 17 inch squares out of muslin diagonally twice to make these trianges. I then sewed theses trianges to each side of each block. I trimed the edges off of each side as shown here. You can see that I didn't loose any of the block to excessive trimming.
Then the finished blocks look like this:
Because there were only 23 blocks I added to blocks to the bottom left and right with the center square filled with the border fabric. It matches the original fabric nicely. Here are the filler blocks.
I then cut down all the blocks to eighteen inches. All the blocks were preserved in the original size and state. I then added two inch finished sashings and corner stones, and just a three inch border. The quilt finished to 106 x 106, which is a little larger than I wanted. But I am glad that this remained my customer's quilt, my influence was minimal. Quilted all over with Joann Hoffman's feather meander. And here is the finished quilt. All I need to do is finish the binding. And get it back to my customer.
