Oh gosh, I thank you all for your detailed and thoughtful answers, and yes, I loaded this with questions, didn’t I!! 😬 All of your advice sounds very reasonable and doable, so I am convinced that I will begin doing this. I may even start through my stash of yardage and make loads of darks and lights to get started on it. I don’t remember having such a nose problem in past years. I wonder if the chemicals have changed, or I have just built up an intolerance to the dust! I always wash my finished quilts before gifting, with the chemicals in mind, but for some reason never thought about my reaction to them. Thank you all again for taking time to respond and being so helpful!