Fixing warped smaller text due to 'Align to Pixel Grid'

Hi
Hoping someone can help.
For my fabric design business I usually create a 16.5x16.5cm artboard add a 16.5x16.5 cm rectangle and then add my text, making a repeatable pattern, before selecting it all and copying it onto a 33x33cm for print. However lately I haven't been able to get my rectangle to stay at 16.5cm, it kept changing to 16.51x16.51cm so I did a bit of research and started unselecting 'Align to Pixel Grid' when I created a new document. However once I selected my whole design before copying it to the larger artboard, it would always be at 16.5001x16.4747 or something like that so I would have to check,uncheck the 'Align to Pixel Grid' box in the Transform panel before I could finally get it to all stay at 16.5x16.5cm otherwise my designs were coming out with gaps between them.
Now all of my smaller writing is printed out warped, which again after researching it seems to have something to do with the the pixel grid. Can someone please tell me how to fix this. And why all of a sudden I'm having these problems! I've been using this method for months and have never had a problem.
Thanks

Carla,
I am afraid you will have to start over, more or less.
It may be possible to rescue parts if you have saved earlier versions with undistorted parts of artwork.
And it may be possible to correct simpler (parts of) artwork by moving Anchor Points with the Direct SelectionTool or something, based on the difference between desired and present dimensions.

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