I made my husband a quilt using some of his old (beautiful) cotton shirts in the blocks, and I made cornerstones for the solid sashing out of the plaid fabrics, and also a scrappy border using several of the plaid fabrics. They actually worked the opposite of exploding head since they provided a straight cutting and sewing line....and mind you I was working from pieces of a shirt...sleeves, etc. I say go for it. I think you (and he) will love it.