Since he is part of the new army and wants fleece as the backing, I doubt very much if he wants a traditional top with blocks and sashing. Why not a whole top, the shadow block as suggested appliqued (glued) his t-shirt emblems glued on, all set somewhat wonky so the size absolutely won't matter? Then stitched down.The edges can curl or fray as he wishes. This is probably going to get rolled up and put in a duffel bag and he will love it - and you.