I made a king-size tee shirt quilt about ten years ago with NO fusible. :shock: The quilt is washed constantly due to dust allergies and
while the woven-fabric sashing is wearing out,
the tee shirts are just fine.
The sashing worked as a stabilizer while sewing the
top together. I will be making another quilt soon and don't plan to use fusible in this one either. I did make slightly wider seams (about
1/2 inch) and most of the tee shirts were fairly new.
I don't know if this is the same process, but I know that there is a book titled "Too Cool T-shirt Quilts" that has a process that doesn't use stabilizer. I just haven't bought it yet.