I would also do a google search on repurposing/recycling jeans. Denim fabric is closer to the fabric weight you will be dealing with. Shirts are great & I use them all the time, but patterns for shirt cotton may not be suitable for the fabric weight you are planning on using.

A while back Nancy Zieman had la ady on her show that made a quilt from her DH and SIL old uniforms. It was amazing how she incorporated all the different army designs into one quilt. Although it was fairly heavy -it was very interesting.
Don't know if you be able to find it on her website but it might be worth taking a look.

So far it's going great!! My wrist does hurt a bit, but that's nothing new! I am getting some suprise fabric that was sewn over other fabric, two blocks for the price of one!!! :) And, surprise, the inside of the pockets are also camo! lol That was fun. I am keeping some pockets in tact that I might use for the purses. If I need the fabric, I'll cut them...but, if not...already made pockets that I can stitch on...uh, somehow...

sewing with nancy recently had a guest who made a quilt using uniforms. I think within the last two weeks. She also had some "store bought" fabric in her quilts, but you might get some ideas about how to use cuffs, plackets, etc. Her shows are free on her nancyzieman.com website. Don't forget to show us what you come up with!!

I found the book on Amazon. It's called Deploy that Fabric by Jen Eskridge.

:) Thank you all so much!!!!

I de-boned all the uniforms...and sorted them into piles according to the design I came up with.
Which is this crazy thing:
http://i1259.photobucket.com/albums/...psde5c9856.jpg

I have different plans for the blocks that are basically blank. And, I may end up moving them to other places once I actually have all the blocks done and layed out.

Here is a link to the album with my progress pictures that I will be updating as I go along...
http://www.quiltingboard.com/members...bums18260.html

I will start cutting out all my shapes soon, but I think I am overthinking the design a bit much and confusing myself!!

I want my finished blocks to measure at 10" each. So I have to add 1/2" for the seam allowance to EVERY piece I cut, right??? I would really hate to cut all my pieces too small since I have JUST enough fabric with only a few scraps left over!!

With that heavy fabric, it might be difficult to make those stars. Can't wait to see it finished. Yes, you have to add 1/2" to the measurement because you sew 1/4" seam allowance. Is the flight suit the same weight as the camos?

No, should I reinforce it with that fusible backing stuff??

If there is a lot of difference in the weight you might have to. Not familiar with flight suits just the camos.