I've made about 5 T-shirt quilts. Unfortunately, I didn't take any pictures of them. Not quite sure how I slipped up on that one. In terms of size I would say anything goes. I think I sashed all of the ones I made and added cornerstones. However, I have seen lots of them that are not sashed. I guess it's just personal preference. Google "images" and you'll see a number of different ways to make them. None of my customers ever gave me a size they wanted. They were very willing to give me free rein on the creativity and the size.
I preferred using cotton or cotton/polyester for the sashing and cornerstones. It's less work since you would have to use interfacing on that fabric if you go with stretch material. You should be able to judge by the size of one of the t-shirts what your average block size will be. If they don't state a specific size they want I'd just do what I could with what I was given. If they do request a size, once you are given the t-shirts you'll be able to give a ballpark of the size you'd be able to produce. You may find they want a big quilt but there aren't enough t-shirts so you'll have to let them know how large or small you can go. I hope that's helpful.
My favorite was a fairly large quilt I made for a window company in the town where I live. The t-shirts were company shirts from all the years the company has been in business. Lots of shirts with retro-babes on them, race-car type images. Super fun. I believe the owner has it hanging on the wall in his office. It was a surprise gift from his employees. That was a very satisfying experience and they gave me way more money than I asked for which was the icing on the cake.



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