No my sheets were not iron on. They are sashed and sewn in the quilt just like any other fabric square. They were a little stiff, but not terrible, but that may be from the ink in the Epson printer. Next time I'll try my HP, but I was out of color ink and the Epson is direct feed so the fabric goes in the way it comes out so at the time it seemed the better choice.
Your quilt sounds very personalized and your son will love it. My son does his. I know the back on mine doesn't match. I had already purchased the brown when I realized I had to put the USMC emblem on the back. This quilt will get heavy use, but he promised me he'd wash it carefully.
Last edited by irishrose; 01-07-2012 at 09:13 AM.