"Interesting that with the Karo baffles, there's a lot less sewing."
I would just like to add that yes, there is less sewing…but it's a tremendous amount more work to do it (I just did a karo quilt and my previous one was a traditional one):
Cutting — My quilt used (96) 6" strips of baffle material. I was able to cut a few at a time but it's still far more work than cutting 16-20 strips that are 30-55" wide.
Measuring — Rather marking every 4-4.5" along the edges and connecting the lines, you're doing every 9-12" along 4 sides and then drawing
Sewing — This is actually the worst part, IMO. Even once I got into a rhythm, I was spending 4-5 times longer aligning my shells and baffles than actually sewing…with long straight lines, it's much more efficient use of time. Overall, the sewing alone took me around 4 hours for a Karo quilt but only around 2 hours with my traditional quilt. I had a lot more confidence in my sewing skills for the Karo too.
I think the best use for Karo is a sewn through quilt. It reduces cold spots without dramatically increasing sewing time.
I'm pretty adamant that Karo is lighter and performs better but manufacturers refuse to use them because of the massive dent in construction costs.
In the next few months, I'm going to be making some quilts (at least two, likely four):
(2) 50F Karo (sewn-through) quilts — I'm actually thinking about using two different pattern (maybe a hex for one) so I can experiment with new ideas and also tell them apart)
(2) 30F traditional quilts
I find Karo quilts to be incredibly attractive but they are a ton of work to actually make. I think everyone who's passionate about MYOG should make one but I think only the die-hards will stick to making them because of the huge time/effort sink.