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I really appreciate all the comments.  This fabric and these chairs are the perfect storm of how to make a job look really shi**y.  I would rather let my sewing machine rust and my scissors cut paper than to do a bad job. 

I think (I know) my dilemma now is how to present this to the customer...I do not want her to think that I am challenging her taste.  They *are* beautiful wingbacks..and the fabric is nice too.  But together, they will not give her the result that I think she wants.

I do (because I collect wingbacks) have a matching pair of wingbacks that I will trade her for hers..mine will work beautifully, they are much straighter wings and the front cap on the arms is waaay more simple and easier to match stripes, plaids. 

Like I said, I've been doing upholstery for over 25 yrs and this is something that doesn't happen often.  (like maybe once every twenty years.)

At this point, I am not going to make any money on this job, and that's not the issue..I just want to do the right thing for our craft AND the customer.
Any suggestions on how to open the conversation would be appreciated.
Perry

I have done, and re-done these wings at least 4 times.  Each time, I address something different.  (so that I'm not doing the same thing over and over and expecting different results, the definition of insanity, say some)
I have literally worked with a level and even with lines being perfectly straight, with all the curvature on these wings, the large plaid looks like it's going downhill. 
I've done the most meticulous relief cuts ever, and still looks like garbage..
I've given up on matching the entire chair, all the elements, at this point, I would be happy if I could just match the IB, the IW, OW and OB..
I have been able to match a vertical benchmark and keep it straight. 
At this point, I'm just trying to gather my thoughts on how I'm going to tell this customer that this really isn't going to work.  And not have her think that I'm insulting her taste. 

I actually have a pair of wingbacks in my shop that are mine, and I am willing to trade hers for mine, and recover the traditional non-curvy wings, it will tolerate the large plaid nicely.
I hate stuff like this.

Muslin, precovering, doesn't help.  I think this is the perfect storm of excessive curves in the very prominent wings and the extreme tightness in this fabric.

One of the things I always say to myself as I'm working is this.."what am I asking this fabric to do?".  The answer to that question in this scenario is I'm asking the fabric to turn several directions AND maintain straight cosmetic lines AND matching..

This fabric has the same feel, tightness in its weave as Sunbrella..

Perry

I've been an upholsterer for over 25 yrs.  Been in and out of the business end.  I hung my shingle back up last year and business has been ok.  Presently I have two wingbacks that are giving me fits.  The chairs are classic wingback, with very prominent and curvy wings.  The fabric is not helping matters.  It is a plaid, the feel of the fabric is crisp and tight, with absolutely no give going around any curves.  The plaid issue is huge, matching vertical and horizontal and I am bonkers. 
Has anyone ever told a customer that a particular fabric just won't work on a certain style?  I've only done that once before about 20 yrs ago...
I am losing sleep over trying to figure out how to make fabric lay smooth and still match stripes, plaid coming and going...
I can take and post photos too, if anyone has suggestions.
Thanks.
Perry

I've done it all. Rented, worked (literally) out of the house and now work at home in a dedicated building for upholstery.  They each have their advantages and disadvantages.
Perry
Jackson, LA