I have a fairly heavy weight 100% Cotton for the outside. I have pre-shrunk it.
For the liner I have a medium weight fleece.
Making the shirt one size larger than normal to allow room for the liner when it is worn.

The question I am pondering in the grand scheme of things is this:
Do I sew the outside and liner together at all seams or just at the sleeves and neck? Then close it off with hem at the bottom.

I am thinking that there is going to be some amount of stretching of the liner when putting on and taking off. How do I minimize that? Any ideas?

I have a commercial made lined shirt. It is attached at the neck and sleeves and loose at the bottom.

that help?

Close it off at the sleeves and bottom. Leave the neck open. If it becomes necessary you can stuff in more insulation such as dried grass and leaves or shredded newspaper.

Thanks dreadstalker! I suppose I should have taken the time to look at one more closely than the price tag. And Rancher, Hubby likes the idea of being able to add more stuffing in a crunch. Gives me something to work with on this project. He's getting me some digital pattern material and sacrificing an old set of combat fatigues for me to dismantle for a pattern. That one may prove interesting. I have already done the same thing with a parka cover with great results. He found liners at Goodwill that buttoned in perfectly, so I count that one as a success.

Thanks guys! I'm off to the treadle machine to see what comes from what I have on th drawing board.

Would you post some pics when you're done Joyce?

When I made a wool Viking Tunic that was lined with silk for DH, it seemed to work best to make two shirts (the inside silk one slightly smaller than the outer tunic. Then tack at neck and sleeves then to hang it up for about a week for the fabrics to stretch as much as they were going to. Then I tacked the bottom (but did not sew all the way around, just in places) to keep the lining in place.

He's still wearing it about 13 years later, and it still keep shim warm and looks OK. Well, its somewhat ragged around the edges now, but that's from wear, not a fault of the pattern.

Rancher do I need to go thru photo bucket to post pics here? It will be a while before I have pics letting the shirt hang out like suggested.

disastercat, so a week of hanging takes care of the stretch problem. Good to know. I'll give it a try.

You can use photobucket or pretty much any other photo sharing service. Photobucket seems to be the easiest to use.