Bob: I am out of town and don't have access to my shop. Here is a quick diagram of the alignment block I was trying to describe when doing rub joints. It basically forces the outside edges to be aligned evenly. I noticed in your post 118 a few segments are sticking out from the others.
The block has to have a good flat even surface. when finalizing the rub joint the one segment is placed flush against the block. the second segment is pressed against the joining edge of the first segment and pushed till the corner hits the block. I hold them in place for 15-30 seconds, then set them aside to dry.
Give it a try and see if it doesn't help in getting the outsides to match up.
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