To update everyone, I have opted to use the sew-n-bond to iron the stars onto the shirts, and then hand stitch the edges. It takes roughly 4 hours to do one shirt, so it's a long night in front of the TV.

I have two done with felt stars, and plan to do two more using a white teeshirt - the iron on seems to seam the edges and should prevent fraying. I also have two done with iron on transfers, so that's six shirts. If each one can survive 12 washings, I'm good for the summer.

I'd like to make more - hopefully I'll have the time. Perhaps use other types of fabric, so if one fails the other shirts won't. I'm thinking hand washing them and hang drying them.

So that's the update... thanks for all the advice and suggestions, I do appreciate everyone's valuable time.

-JoeJoe