Yeah, I've been playing with several different ways of making a stitch pattern. I created a couple different brushes but they don't look good unless you round the corners or make a corner for the brush. I also used the transform zig zag option. That can be problematic because it fits the frequency between each point on the path. If you have evenly distributed points, it looks fine. If you have a irregular path, some areas will have a high frequency pattern and others will have very low frequency. So far I've have the best luck with using the appearance pallet and adding different dashed strokes. They overlap in the corners so it kind of looks more like a stitch.
A nice addition in CS3 is the Smart Objects and Smart effects. With it I can bevel an object and then turn it into a smart object and do a stroke bevel with a texture to make it look like thread. You can even create a smart object from a smart object. It sounds weird but it allows you to do multiple effects on top of each other. When you cut and paste Illustrator paths and objects as smart objects you can double click the smart object and it opens it in a temp Illustrator file so you can edit it. Right after you save it updates the Photoshop file with the changes.
This whole BSG patch thing has been a nice learning experience.
right after i sent you that comment I turned on my other PC and made a stitch brush its not that hard dont know if i will ever use it... but still cool can you post a close up screen shot of your stitch or brush?? I just wanna see how you did it?? if you dont wanna thats cool too
Sure I'll put the ones together that I did for this and post a screenshot. They aren't that hard but cornering can be a bitch if it's more or less than 90 degrees. That's why for most of them I just did a modified dash stroke with the square butt cap. For the circles it was easy since it had no corners and even'ly spaces points. On those I used multiple strokes in the appearance pallet with different zig-zag transforms.