My husband is one of the nay sayers of Badge Magic, so I have to sew all of the badges on our uniforms. Sharp needle, short stitches, mono filament thread. I must admit I cheated on the Cub Scout uniform and bought the diamond plastic holder, so that the pocket was still usable. My hand did not fit in the pocket to sew the Tiger badge on.
For a Tiger project, felt cut into 18 inches by 2.5 inches and folded over to make flaps works great as a pencil holder. You can put a button on to hold it shut, and no sew button hole, because felt doesn't fray easily. The felt is easy enough to sew through so you can use the hand embroidery needles which have large eyes and dull tips. It would be much easier than having the little guys try to sew through the embroidery on a patch.
If you have access to a few sewing machines, making pillowcases are a breeze!
For Bears, we are going to make polar fleece hats. I have a few sewing machines, and the boys will be learning bits about sewing. I am not sure what requirement/elective this will gain for them, but I want them to learn the skill. We have a winter event in our council, and we will be the only den there with dinosaur hats, making my boys easily identifiable -- the true reason behind my madness!
Have fun!