If you want one made, there are companies and quilters everywhere that make them.
As for cost, the idea that they are expensive depends on how you view the work. I love quilting but understand that what I sell them for keeps me in fabric. I'm not earning a living from it.
Usually this means getting them all together, calling around to find how much it costs to actually make a quilt, then putting them back in storage.
Takes a lot more time and effort to make a quilt than people think.
It was made before we met, so I don't have a sense for the cost. As a functional swaddle of memories, it is worth far more than a blanket from the store.
One thought for those considering it -- the shirts can't be completely worn out. A threadbare shirt will make a threadbare quilt.
T-shirts already have a front and back. You just need some long running stitches to join two shirts together. Shove them with the amount of batting you want, and then another running stitch to seal them up.
Hand sewing a quilt is a big effort. If you love doing it, it's awesome. If you don't, it's just massively frustrating and time consuming.
I say this as somebody who hates all parts of sewing except old machines.
I think you found the next YC business idea
These are shirts I've worn for a week straight trekking through Central American rainforests.
However the cotton fabric used in most off the shelf clothing is also not what it used to be. My dad, who doesn't like to throw things away, still has his old clothes from when he was in his 30s (he is in his late 70s now). They've retained their shape far better than my 3 year old clothes.
I've had phenomenally gross post-ride jerseys (literally crusted with sweat), but doing this they don't get stinky. I agree that the key is to not let them stay wet and let bacteria grow in it. Get them dry fast, all is good.
Over here in the UK and much of Europe, the charities sell them by the ton to traders that ship them to Africa or other developing countries.
Some charities don't even handle them, they enter into a contract with a third party that specialises in the trade that collects the clothes and then pays the charity a fixed amount of money per ton. The whole service is branded, so you would think that you're donating to the charity directly when in fact they are paid by the trader by weight.
They also have a book company who have a similar arrangement, they pay a few pence per book, though IIRC they do make use of the books as-is rather than shredding.
Donated stuff is treated the same way, and just the proceeds used as a donation to help the third world. Read the fine print on the used-clothes-bin.
Regardless, even when they were shipping them out, the environmental cost of shipping and repurposing was always higher than the cost of just using what you had.
Amused by family pics where I recognize a garment that's older than my oldest kid being worn by the new toddler.
What's the secret?!
The problem with the most department store jeans, no matter the price, is that they use fabric made on high-speed wide looms. These looms use light and smooth thread so they can weave fast. The fabric comes out very light (because of the thin thread) and does not hold together quite well (because the fabric is held together by friction, reduced by the smoothness of the thread).
Of course, it makes no sense to buy expensive jeans for durability. $400 24oz jeans probably will last for 20-30 years but so will 10 pairs of $40 jeans from Target.
Thickness counts for durability, and you have choices. I'm not sure what durability is like for cotton blends (it's rarely more than 3-4% synthetic). I have doubts that mass-produced denim of similar weight is significantly more or less durable than denim from traditional looms. The only differences I can think of that would impact this would be staple length and chemicals used in processing. Pre-faded, bleached, or distressed denim will obviously be less durable.
20 years sounds high to me. I have jeans less than a year old already showing crotch wear. Granted, this is expected, and it can be repaired before it's an issue.
For work (if style is less of a concern), Duluth Trading makes pants that last an order of magnitude longer than carhartt.
A word to the wise though; while my raw denim jeans are several years old now and in good condition, you sounds like you're dramatically harder on your clothes than myself.
https://www.nextdirect.com/CountrySelect
They do look worn, but I don’t care.
Lately though this hasn't been going as well. I think partly due to Covid lock downs I've gained some weight around the middle and some jeans no longer fit. I'm resisting buying replacement jeans hoping to lose the weight instead. Not going well so far.
The best thing you can do is buy quality clothing, take good care of it and repair it when necessary, before it wears out completely. That can extend the life of an item significantly, but not indefinitely.
Buy good quality wool, wool blends, thick cotton twill, heavy selvedge denim and similar fabrics. They're durable and take repairs well. I've never had much luck with hemp, and linen is too fussy for me, but I'm not ruling them out.
If you don't mind synthetic fibers, you can get some very light yet durable clothing. The drawback is that a lot of it will come from outdoor brands and look like it.
By dispose, what you mean is send them to Africa or other undeveloped regions. In virtually all of the 35 African countries I spent time in I would see clothes for sale in local markets that still had (St Vinny's/Goodwill/ Salvation Army) tags on them.
The idea of buying clothes then donate them after 6-12 months has always been broken. With growing kids (or if you gain/ lose a bunch of weight) you don't have a ton of choice. For most adults, the only way you can really ensure you have an environmentally friendly wardrobe is by purchasing carefully and keeping clothes until they genuinely wear out. For jeans and good quality jackets, that can be decades.
When you donate clothes to St Vinny's (Goodwill/ Salvation Army/ whatever), they keep the best/ resealable clothes and dispose of the rest. A bunch gets dumpstered. The only reason they accept used clothing is because of the small percentage they can actually resell.
[1] Excluding underwear and socks!