Oh Craftylady sorry no help here!
But certainly keeping my eye out for this post!
I love Thomas too!

Thomas the Tank is a licensed design, don't think you will find free designs, you have to pay for the card, which I think OESD has licensing for and includes a thread kit. There is plenty of fabric and other things out there you might be able to do applique work with.

I have Thomas the Train but I can't think right off who made it, OESD sounds right. It being licensed does mean it is something you will have to buy.

im in the prossess of diging all these up at the moment. ill share them out when they are finished to all you good peeps....watch this space

Craftlady, is this what you're looking for?

http://www.joannapullen.com/products.php?cat=16&pg=2

For some reason I can't get it to load correctly. But this is the site where Thomas the Tank train is and it's also a feebie.

There was a Thomas the Tank design on ebay a while ago but knowing it was licensed, I was leery of ordering it. It was not free but it was fairly inexpensive. My grandson is crazy about Thomas the Tank. but I did not order it.

Here are two great Thomas the Tank Designs. Stitch out perfect!

http://www.blastostitch.com/embroidery_pattern_details.php?item=Thomas%20the%20Train%20Stitched

and

http://www.blastostitch.com/embroidery_pattern_details.php?item=Thomas%20the%20Train%20Applique

Here is a link that might be useful: Blasto Stitch