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I've been looking for a plain orange onesie for DD's halloween costume, and it is surprisingly impossible to find. Can you recommend a dye for a shirt? After dyeing it I would still be able to iron things, like a jack o lantern face, on right?

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Re: fabric dye
You can find plain orange onesies- they do exist. But, it's really easy to dye 100% cotton fabric. I like Dylon- they have a nice pumpkin-y orange. I get them from Joann's. Rit works fine, too- but, get the liquid dye, not the powder.
You should know that the polyester thread likely won't dye with either of these dyes, though. And cotton/poly blends won't dye as nicely.
No problem ironing on appliques or heat transfer vinyl with either dye. I think MADE by Dana (blog) has a nice walk-through thing for dying clothing- she does a lot of that. I generally dye yardage- so I can't get away with the little bowls she uses, and I usually do a bunch of colors at once, so I can't do the sink basin. I generally use big black buckets from the $ store and plastic mixing spoons to stir.
Do you have an Osh Kosh store in your area? Closer to Halloween, they have tons of stuff in their stores. Here's an orange onesie for an 18 mo old that you could get online. Though, if you have a store, I would go there... tons of Halloween outfits, socks, shoes, and hair accessories to match.
http://www.carters.com/null/Ruffle-Sleeve-Cotton-Bodysuit/702371416410,default,pd.html?cgid=oshkosh-baby-girl-bodysuits
If you aren't interested in that, I've used RIT dye before. Use on 100% cotton or other natural fiber. Dye a couple of times to get the color darker.
Newlyweds since 2007