Eileen I could eat your rhapsody quilt. It's gorgeous

I make t-shirt quilts for clients all the time. First, you need to stabilize the shirts to minimize the stretch. I use fusible tricot for this. To make it as large as you'll probably need, cut the shirts to a uniform size, with sashing in between. The badges can be appliqued to fabric patches cut to the same size as the shirt blocks. The border/borders can help bring it up to a size that will cover him comfortably. If you go to my website, http://www.designingquilts.com , I have a couple in my photo gallery. I've also got a few pics on my FB page, https://www.facebook.com/pages/Eileen-Keane-of-Designing-Quilts/143067942379277, I've got a few more.

Hope this helps,

Thanks for the info!

Welcome to the forum, Mimi!

If you will do a Google search or Pinterest search for tee shirt quilts you will get lots of ideas for layouts and construction tips!
Also you will find lots of great info in this book: http://www.amazon.com/T-Shirt-Quilts-Made-Easy-DeLeonardis/dp/1604600144/ref=sr_1_1?s=books&ie=UTF8&qid=1370375383&sr=1-1&keywords=tee+shirt+quilts
Check for it at your local quilt shop!

I have 18 t shirts and 12 "badges" depicting the 11 years of my sons military career. I want to make a quilt for him but not sure how to design this. He has asked for a quilt big enough to cover him ( he is 6'3") and be able to cozily wrap himself in his military memories. I would love some help on designs others have used. The t shirts are tan and black, his uniform shirts are in tans, greens and browns which I plan on using in the quilt as strips or something in each square. Please help!
Thanks, Mimi