Yes, I have made flannel rag quilts. They are really warm and the more they are washed the softer they get. I made one for my sister for Christmas and she said everyone fought over it, so I made one for my bil and nephew the next year. Then my dd asks when will she get hers? So I guess I will be making more for this Christmas!!
I think the most common is 6 1/2 by 6 1/2. I bought some flannel pieces on e-bay recently and they are small rectangles, so this one is going to be cut 6 1/2 by 3 1/2 and I will make it like bricks, off setting each row. I'm going to save the pieces and make a string quilt! Can't waste any fabric!
I've made lots of these, as well as the chenille quilts. My only suggestion is to make it larger than you want it to be...they shrink a LOT when washed, especially if you use the cheaper flannel. And make sure when drying it that you stop the dryer about evey 15 minutes to clean out the lint!
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