CCL mentioned this in her thread and I am working on some myself. Mine are about the size of a baby blanket and have batting in between washable poly/cotton. No handquilting - just handtied with heavy yarn, double tied every six inches on so - enough that the batting does not shift. I think the size is about 17x23 (allowing for seams) so one yard of 48" fabric is enough for *two. Or, I may get some flannel to use on one side. It should fit nicely in a cage or carrier and I hope it will go home with the kitties!! But whatever they choose to do with them is fine. Sew it like an inside out pillow case, back to back with the batting and turn and stitch the final seam. If anyone has better instructions, or knows what the shelters prefer - please let me know!! The old blanket is an excellent idea and I am sure much cheaper than the batting! Thanks!!
* edit I said a yard makes one but it actually makes two!..it will make FOUR if you use a plain muslin for one side.
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