We get new patches every year in Indiana so we have to remove the old ones. My wife uses a seam ripper (I think that's what it is called) and it removed them OK. After a couple years, small holes do start to develop where the stitches were but that's usually not an issue since the new patch goes over it. In 2006 they used a much smaller patch which didn't look good on the worn shirts. Last year then went back to the regular patch and all was good again.
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