I've made a t-shirt quilt for each of my two daughters for high school graduation presents. The use of non-woven fusible interfacing was key to keeping things square. There are lots of different weight interfacings, so experiment until you find your favorite balance of stability without creating a cardboard stiff fabric.
It was very important to me not to cut off designs or end up with huge amounts of 'blank' space, so I made blocks in several sizes and grouped them. I ended up liking the non-structured appearance of this kind of layout. I also took the pocket designs from the polo shirts and t-shirts and put them together to make one block.
ALSO - watch your iron temp when fusing the interfacing as it can melt/smear the t-shirt paint!
The only photos I have access to right now are of the top, but here's the top and the 'pocket' block. I'd be happy to provide more details on the planning and layout, so pm me if you'd like.
Mark
Last edited by stormwater; 07-19-2012 at 09:07 AM.