Here's the info on the quilts we make for Ronald McDonald - 6" squares - either 7x7 or 5x5 with a border - all cotton with machine stitched binding- washable. If each member of the troupe did one square - you can use Moda solids and have them use permanent Sharpie markers to decorate or find a square they can cut and maybe sign with a Sharpie. I'd keep it simple and let the boys take charge as it will be therapeutic for his friends as much as for the patient. Here's a link to the Ronald McDonald page for ideas. (remember hospitals have to be concerned about germ control)
http://www.rmhcincinnati.org/sites/d.../Quilts(5).pdf http://www.rmhcincinnati.org/sites/d...ern%206(1).pdf or this crib size
http://www.rmhcincinnati.org/sites/d...20Patch(1).pdf