Welcomel to the board. You will find everyone on this board is so kind and full of ideas and advice. I too am making a denim quilt out of my Dad's jeans and I am cutting 9 1/2", 6 1/2" and 3 1/2" squares. I cut the bigger squares whenever I can and then when I come to a smaller area I try and get the next smallest size. They will all fit together since they are in increments of 3's. Good luck to you