I have been doing all the tests suggested with the templates/printing and although like you my centre circle came together without any problem, I became increasingly worried about the exponential effects of any loss or gain in the measurements. I did measure up my join so that the grid squares measured 2" but after all the messages posted I went back (after I had made the centre) and measured the whole of the sheets and found some discrepancies amounting to 1/4" over the entire length of the page. I could not get the test page to measure accurately which suggests that neither of my printers measure to that degree (an HP laser and an Epson inkjet). We looked at other solution to printing documents with measurements. Architects would seem to have the same problems because printers don't think in measurements they think in dots per inch and they get round it by using plotters or very high spec printers generally found in industry and not in households. I have taken a test page to a speciality printer today which thankfully looks OK, just need now to get all the templates printed by them. SO, I think to be safe, I will have to do the entire centre circle again!
Just an extra consideration, being a US site, the templates , I think, are designed on US letter size paper and not on ISO (International Standards Organisation) sized paper, A4. International members/BOM'ers need to be aware of this as it can also cause problems.
This is my first TQS BOM and having got excited, chosen and bought fabric etc, I am feeling a little disheartened about all the printing problems and the possibility that it might not work out. Hopefully my solution will work for me but I don't think I will feel wholly comfortable until I get further down the line and things hopefully fit together.