Alignment issues are always most prominent across straight lines. Beginning stained glass crafters have so much to pay attention to that once something fits they just assume that it is correct, but that is not always the case. We want things to not only fit, but align correctly as well.
Look at the pieces that form the corners of the two borders in the picture below. They fit, but they do not line up correctly. The orange arrows in the image on the right highlight the problem areas where alignment is off.
Here is the same border with perfect alignment. Note how the lead lines connect perfectly as they cross paths (highlighted in red).
Paul
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