Read this once before you start. It takes about 5 minutes and will save you days at production.

Your quilt price is low because our process is dialed in. The single biggest cause of delays and extra fees is shirts arriving in the wrong condition. Follow these four steps and you're golden.

Before You Begin: What You'll Need

• Your order confirmation email (search your inbox for "Project Repat")

• All the t-shirts you want in your quilt

• A pair of scissors

• A tape measure or ruler (12 inches minimum)

• A box you can ship in (any sturdy used box works — Amazon, USPS, etc.)

• Packing tape

• A printer (for the shipping label and packing slip) — no printer? See No Printer? No Problem.

⏱ Time to prep: About 10 minutes per 10 shirts.

The 30-Second Summary

1. Count the right number of t-shirt sides for the quilt size you ordered.

2. Measure each side to make sure the graphic fits inside a 12" × 12" square (or 14" × 14" for our larger panel option).

3. Separate the front of each shirt from the back by cutting up the side seams.

4. Pack & Ship using the label and packing slip from your order confirmation email.

That's it. The rest of this page explains each step in detail and what to do if something is unusual.

Step 1 — Count Your T-Shirt Sides

What's a "t-shirt side"?

Every t-shirt has two sides: a front and a back. A "side" is one of those — usually the side with the graphic you want in your quilt.

🧠 Quick example: A shirt with a logo on the front and a sponsor on the back = 2 sides, if you want both. A plain-back shirt = 1 side.

How many sides do I need?

Match the number of sides to the quilt size you ordered:

Rules of the road

• ✅ Send the exact number. Extra sides won't be returned, and missing sides will delay your order.

• ✅ Double-sided quilt? Send TWICE the number. A double-sided Twin needs 48 sides, not 24.

• ✅ Not sure if a shirt makes the cut? Send a few extras as backups — but mark them clearly on your packing slip (see Step 4).

  💡 Pro tip: Lay your shirts out on a bed in the layout you'd like before packing. Take a phone photo — you'll need it if you decide to order a custom layout (Step 4).

Step 2 — Measure Each Side

We cut each shirt into a square panel. To make the panel look great, the graphic has to fit inside that square with a little room to spare.

Minimum size for each t-shirt side

• Standard panel: Graphic must fit inside a 12" × 12" area.

• Large panel (if ordered): Graphic must fit inside a 14" × 14" area.

How to check in 5 seconds

1. Lay the shirt flat.

2. Place a ruler at the top of the graphic and another at the bottom.

3. If the graphic is less than 12 inches tall AND less than 12 inches wide, you're good. ✅

4. If it's bigger than that — that's a problem we can solve, but the edges of the design will be cropped. Decide whether you're okay with that before sending. We have 14x14 squares, and also you can request 16x16 squares.

Important rules

• 🚫 Do NOT cut your shirts into squares yourself. We need the full side (sleeve to sleeve, collar to hem) to align the graphic properly. Pre-cut shirts can't always be used and may incur a fee.

• ✅ More fabric = better. Keep the sleeves on. Keep the hem on. Trust us.

• ⚠️ Tank tops, v-necks, and graphics near the collar may need extra fabric added behind them ($8.99 each — see Fees).

Step 3 — Separate the Fronts from the Backs

This is the one most people skip — and it costs $2 per shirt if we have to do it for you. Don't skip it.

How to do it

1. Lay the shirt flat.

2. Cut up both side seams, from the bottom hem up through the armpit, then across the top of the sleeve.

3. You should end up with two flat pieces: a front and a back.

4. Keep the sleeves attached to whichever side you're sending. Extra fabric helps us center the graphic.

   📹 Visual learner? [Watch our 90-second how-to video.]

If you're only sending one side

You still need to remove that side from the shirt — don't send whole intact shirts. Cut the side you want away from the side you don't, and recycle (or save) the unused half.

Step 4 — Pack, Label & Ship

Getting your shipping label

1. Open your order confirmation email from Project Repat.

2. Click Step 3: "Get my shipping label" (you'll buy the label directly from our site at our discounted rate).

3. Print the shipping label — tape it to the outside of your box.

4. Print the packing slip — fill out the checklist and put it inside the box with your shirts.

Packing your box

• ✅ Any sturdy used box works (Amazon boxes, USPS Flat Rate, etc.).

• ✅ Tape it securely on all seams.

• ✅ Fold shirts flat — they don't have to be perfect. Stack them inside.

• ❌ Don't include loose notes or special requests in the box — these cause delays and may incur custom-work fees. Use the order confirmation portal for any changes.

After you ship

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No printer? No problem.

• FedEx locations can print your label from a QR code or email — bring the confirmation email on your phone.

• The packing slip can be hand-written on a piece of paper inside the box: name, order number, number of shirts enclosed, and any notes.

What Materials Work?

✅ Works great

T-shirts • Sweatshirts & hoodies • Tech / dri-fit fabrics • Fleece • Flannel • Scrub tops • Basketball, volleyball & hockey jerseys • Golf polos • Polos

⚠️ May work (with $8.99 alteration fee each)

Rally towels • Button-downs with logos near the collar • Polos with logos near the collar • Undersized tank tops or sleeveless shirts • V-neck shirts • Cheerleading tops • Puff paint designs • Rhinestone designs • Pinnies

🚫 Can't be used

Denim / jeans • Shirts with zippers • Silk • Sweaters • Knits • Canvas • Nylon jackets / tracksuits • Leather • Letterman jackets • Wool • Lycra / spandex • Dance & gymnastics leotards • Sequins • Down-filled items • Women's blouses • Satin • Graduation gowns or sashes • Tote bags

❓ Unsure about a specific shirt? Email a photo to madeinusa@projectrepat.com and we'll tell you within 24 hours.

Potential Extra Fees (and how to avoid them)

We hate surprise charges as much as you do. Here's exactly when they apply and how to skip them.

💳 Custom-work invoices must be paid before your finished quilt ships back.

Managing Your Order

All changes happen through your order confirmation email — search your inbox for "Project Repat."

Click "Step 2: Verify my order details and see available upgrades" to:

• Change fleece backing color

• Update your shipping address

• Change panel size

• Add upgrades (binding, double-sided, etc.)

• Upload a custom layout photo (+$25)

Common questions

Can I customize the layout?
Yes — upload a phone photo of the layout you want via Step 2 in your confirmation email. $25 flat fee.

Can I add or remove shirts after I order?
You can ship a different number of shirts than you ordered, but it may change your quilt size or trigger fees. If you need to change quilt sizes, do it through your confirmation portal before shipping.

How long does it take?
Production times shift seasonally. Check the current estimate on your order page or in your confirmation email.

Still Have Questions?

• 📧 Email madeinusa@projectrepat.com — we reply within 24 hours.

• 💬 Visit our Help Center.

• 📷 Send us a photo of any shirt you're unsure about.

We're a small team in North Carolina that has handcrafted over a million quilts. We genuinely love the stories behind every t-shirt you send. Let's make something great together.