Ann, Lorna is right. You need to re-measure your 1" test square. It must be EXACTLY 1"x1". Even just a tiny bit small will not work! When you print out your foundations, be sure that your printer scaling is set to "none". Sue give directions on pages 3 & 4 of the Introduction. Don't feel bad....you are not the first!
You want to figure this out now, because if your blocks are not the prescribed finished size, the whole project will not fit together well.
As for the precision piecing....you may want to check out Alex's classroom from June 2008. She did a series of several videos about piecing Leymone Star blocks and shows how to piece points.
(Access the classrooms on the purple bar under "Classrooms")
You can also access my "test" on my Webshots album to make sure that you are stitching a 1/4" seam allowance. You can access it here:
http://good-times.webshots.com/album/569415726bHNKHF
Good luck!