Here is a link to one that I did that all the blocks are cut the same size and set with sashing and cornerstones. I used the small pocket imprints as cornerstones.
http://www.quiltingboard.com/picture...lt-t47094.html
The border was made simply sewing the T-Shirt blocks together.
I have made close to a dozen T-shirt quilts in this design, they are quick and easy. I use Pellon featherweight fusible interfacing. I have no trouble attaching my fusible after I have cut my T-shirt but some T's tend to curl a bit upon cutting. I just can't stand wasting any of the interfacing so that is why I cut a bunch of pieces of fusible and have them at the ready for my cut T-shirt imprint.
Stormwater is dead on about iron heat and melting/smearing the imprint ink. I always use a pressing cloth which is just a scrap of muslin. This keeps me from smearing the imprint.
T-shirt quilts are HEAVY. So be prepared for that. I never tried to quilt one on my domestic sewing machine, I always hand tied them with DNC embroider floss (3 strands). But that was prior to getting my LA. I won't hesitate to LA one and if you can swing it I would recommend sending it out to a LAer to avoid much grief and frustration.
I have written out instructions for how to make the T-shirt quilt I pictured. If you want them, PM me your email address and I will send the document. I never measured how much total yardage you need for the sashing, but I had 5 yards of that fabric, my sashing was 3" unfinished and I had loads left over so I bet 2 to 2 1/2 yards would be ample.