Reading your post gave me shudders! I've made both my kids T-shirt quilts about 10 years ago--before I really started quilting. I just sewed shirt fronts together, they weighed a ton and I ended up just tying at the corners. Flash forward about 10 years and membership in a quilt guild and I've learned (but not done--too many bad memories!) that the way to really do them is to cut the shirt logo only, fuse to Pellon 911 fusible and edge with a cotton fabric and then piece. This allows you to use different size logos, gives it stability, allows you to piece it easier and actually quilt it too. Stippleing on the cotton edging looks really nice and using the edging allows you to draw together the colors in different T's. Like I said--haven't done another one myself,but did learn how from someone that does them professionally! Good luck!