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Your method is create a seamless tile, duplicate it by a set distance etc? That leads to mistakes. Just create a shape of any size and fill it with a single repeating tile, set it to the required dpi...

Here is a seamless tile. You can fit it to any shape of any size and it seams perfectly. Why create a larger seamless tile. If you do just ensure your shape is in multiples of the tiles original...

Ric, I think you're missing my point. You have a perfect small seamless tile, no joins created by misplacement, anti-aliasing or anything else. Nothing to do with creating a perfect seamless tile....

That (#2) isn't seamless.
You have a small seamless tile, why are you trying to create a large seamless tile from it. It's causing issues that shouldn't exist.

Doing this will make it almost impossible to make a seamless tile as you're changing the dpi.
Keep the dpi to the original dpi and set the larger square multiples of the original tile size.

Could...