I had the same idea, but I am using blue hankies, since he will be taking it camping...

I made a sampler out of denim, different colors, 9" blocks, nothing too complicated - moon over mountain, rail fence, flying geese, card trick (with 3/4 square each instead of piecing), raw edge applique, 4 patch, 9 patch. Several whole pieces in different colors of denim. Several with pockets on them, and a handkerchief in the pocket. One square with the zipper, and underwear behind it. I thought of putting a shirt top with color above that like a dickey. One flag block with the stars and stripes made with bleach. If you don't have different colors, you can use the back side of the denim.

It would fray okay eventually I guess. I don't think I would like to do the cuts like for a rag quilt. I think my hands would fall off. And I think you would have to make sure that the blocks are all cut on grain. Just thinking that all those threads would drive me nuts.

If you use wider seams, like 1/2", and press them open, the quilting shouldn't be a problem. You can get a Schmertz demin needle if needed. It's very sharp and pierces the tight weave nicely. I'd like some batting - thin poly wouldn't add much weight. Or prewashed flannel, maybe.