5 / 6 ounce ougth to be about right. Stitch it with regular thread. The only thing that should have to be sewed is the straps and the waist strap is going to around to the side and the neck piece round his neck if he gets the thread burned there he's going to be burned. I would use paper unless you have a old shop apron, if you do you can use it for a pattern. I would tie it in the back like regular apron..