Patty -
I have the same finished sizes as Dawn and Ellen. I also had the "bowl" when I attached the skinny outer border to the pieced border, which I did before attaching to the center star. Fortunately my pieced border and center star looked like they would play well together (and they eventually did).
Like Ellen, I had to unsew. I unsewed the outer border and reprinted the template (#3) and recut the piece. And resewed. I believe my problem was putting the 6 pages of template 3 together. I was super duper extra careful the second time, and when I reprinted it I could see the registration marks which was a great help in putting it back together. I measured the 3" grid all the way across- both ways and many times. In the end, it all worked (yay!). A few other things: 1) I made sure to press my pieces without steam in case of shrinkage. 2) The first time I put the template pages together with 1/4" Steam A seam, but the second time I used a glue stick. I felt I had more control with the glue stick, and less bulk. 3) I spent LOTS of time pinning - I made sure I put the pin in the sewing line on one piece, and looked at the other piece and ALSO made sure that the pin went through the sewing line there. And...4) I used a longer stitch length the second time, because "unsewing" the tiny stitches as much as I did was a REAL pain... I am using Stable Stuf and plan to leave it in anyway.
I know this all sounds really basic, but I am working on my patience skills
I am really glad that I perservered, because I love how it is turning out, and I am really learning a lot! Keep on....