here is a pic of the shoulder patches being "assembled"
i glued down the yellow invader guy first on a larger piece of twill. i then lined up the state of PA halves around it, and glued them into place. i worked from the middle out, rather than placing the state of PA perfect first, then lining up the invader guy. much more wiggle room, or room for error when you work form middle out. i sewed all that down. when finished i placed all the squares and the rectangle onto the newly sewn patch, glued & sewed. then i cut the outline with scissors by "eyeball" only. no marks on the edge of the patch.
credit to TK for the photo! looks great!