As far as the longevity of the flannel, I have had rag quilts that have been used thru three babies and is still going strong. Usually if it is a quality material, it will last for a long time.

Also the fiskars rag scissors. I bought one for my last "rag quilt kick" ( they come and go) lol. It was life changing. Less likely to oversnip. Far less hand fatigue. Consistent fringe length .

I'm really tempted to get that die. The one holdback is you're forced to make 81/2 inch blocks. I like 10-12. Makes the quilt go faster.

I use one inch seams clip to to 3/4. Never had a seam pop. Batting if I use it is block -3, 1 " seam allowance. So 12 inch block finishes 10 and the batt is an inch inside.

I use the triple stitch that is now on most newer machines. I also use a seam ripper and go from the stitches to the raw edge that way I don't cut the stitches. 1/4inch apart with the seam ripper chenilles up nicely when washed.

Are you snipping into the seam? Use small enough stitch? I use about 2.5

I don't try to clip to the seam, either. Stay a bit shy!

Something that I found helped all the fuzz was this: when the quilt comes out of the washer, put it in dryer on a setting that is not heat...a "fluff" setting. Heat seems to set the fuzz and make it harder to remove. Just keep it moving around in cool air and more fuzz, threads, etc seems to come off. Stop the dryer after about 8-10 min an clean out the lint trap and run it again and again until the fuzz, etc gets less and less. The quilt will still be wet but when you do turn the setting to "heat", most of the fuzz, etc will have already been tossed off. At least, I think it helps. Good luck!

I was told to go around the whole outside three times, so far all are still holding.