Selvedge Denim Recap

I have been wearing my jeans for a few weeks now. The denim is softening a little bit, but they are still pretty stiff. Here is a little recap of the process I went through to make the jeans. When I started I didn’t really know much about denim or clothing design for that matter. Over the course of several months though, I learned enough about pattern drafting and construction techniques to make myself a custom pair of jeans.

custom denim

Step 1. I sewed a practice pair in muslin using a commercial pattern. I used Burda 7733 to get a general understanding of the shapes of the different pattern pieces that make up a pair of jeans. When I began this project, I knew I wanted to design my own pattern, but using a  commercial pattern was a good place for me to start.

Step 2. I drafted and test fit a men’s jeans sloper. The sloper is a simple pattern without any style lines or pockets that helps to establish a good fit and basic shape. A sloper can be used to create more “stylized” patterns later.

Step 3. I designed my jeans pattern. Using the sloper from step 2, I modified the shape of this basic pattern to include the pockets, yoke, fly, and waistband. My goal here was to create a straight leg, somewhat slim fitting men’s jeans pattern. After creating the pattern pieces, I added seam allowance to each piece and cut them out in tracing paper.

Step 4. I sewed a second practice pair in muslin. Before cutting into high quality denim, I needed to make sure that the pattern I created in step 3 fit and that the pieces would actually go together properly. Everything went together as planned. Yay for my good work!

Step 5. I sewed the final denim jeans using the same pattern from step 3. Aside from the waist being a little too big and some less than perfect top-stitching, they turned out much better than I expected.

In fact, they have become my “go to” jeans for everyday wear. While I am already contemplating the changes I want to make for my second pair, I may have to learn how to make a women’s jeans sloper and pattern first because my wife secretly wants her own pair of custom selvedge denim jeans. I guess I’ll take that as a complement!

Selvedge Denim Jeans

I finally finished my jeans and couldn’t be happier with the way they turned out. I used a 12.25 oz, raw, selvedge denim from the famous Cone Mills in North Carolina. After working with muslin for so long, it was nice to use some quality fabric that I would actually wear.

selvedge denim roll

My main concern leading up to this project was that the sewing machine (Pfaff select 1526) would not be able to handle the thickness of the denim. For the most part it did just fine. In a few really thick areas, where I was sewing through two flat felled seams (the crotch point and where the back yokes came together), I had to hand crank the machine. This was fine by me because I tend to sew at a snail’s pace anyway.

back pocket stitching

The denim is a bit streaky, which I like because it gives the jeans some subtle texture. I added a branding leather patch that I left blank because I haven’t thought of a name for my “line” yet. I also added rivets to this pair, and lined the fly with the same fabric I used for the front pocket bags.

streaky cone selvedge denim

There are a few changes and improvements I would make on the next pair. The second muslin practice pair I made from my pattern had a little extra room in the waistband. I debated whether or not I should modify the pattern when cutting out the denim. After trying on the muslin practice pair multiple times, I thought that maybe the muslin had stretched, which would explain the extra room in the waist. I also thought the denim would be stiff and I would want a little wiggle room, so I left the extra room in the pattern when I made this pair. I wish I hadn’t because my waistband is still too big. While I can wear them with a belt, I was hoping for a perfect fit.

I would also take in the pattern through the entire length of the leg to make the overall fit a little slimmer. The last change or improvement I would make is to my top-stitching, which I’m sure will improve with time and practice. The top-stitching in the fly area is less than perfect, but will be fine for everyday wear.

back pockets

selvedge fly

The front pocket lining has greetings in multiple languages from all over the world. I used the selvedge on the fly as a way to reduce bulk.

selvedge denim cuffs

Despite the waist being a bit big and my top-stitching wavering here and there, I am thrilled with the way these turned out. Armed with my own pattern and an obsession with high quality denim, I can’t see myself ever buying a pair of store bought jeans again.

Second Muslin Pair of “Jeans”

Once my pattern was complete, I wanted to make another pair of test “jeans” out of muslin before diving into actual denim. Since this was my first attempt at drafting a custom pattern, I was a little nervous that maybe the pattern wouldn’t come together properly. I needed to make sure that the fit was right, and well…that it could actually be sewn.

Prior to this, I always had a set of instructions and the various markings on the commercial patterns I had sewn to guide me. This time around I was completely on my own, which actually made the sewing process more enjoyable. It was quite freeing to not worry about following a set of instructions, and to just assemble these practice jeans in the way that made the most sense.

To my surprise, everything went together flawlessly. They fit well through the leg, crotch, and butt area. I had a little extra room in the waste band, which could easily be fixed in the pattern. The only detail I left off this pair that I would put on a denim pair is rivets. I went ahead and put on the fly buttons for practice. As I mentioned in the pattern making post, I wanted to learn how to make a button fly. I used David Page Coffin’s book Making Trousers for Men and Women to figure out how a button fly is constructed. The book has a section on button flies that was very helpful with step by step instructions.

My top stitching through the fly area could still use some work, but this was a practice pair, and I wasn’t too concerned with making them look perfect. Here is the back side.

I want to make these back pockets a bit bigger on a denim pair, but the overall shape is fine. The top stitching across the back pockets is supposed to make a somewhat abstract pair of “T’s.”

Other than taking a little extra room out of the waste area, my pattern doesn’t need to be modified in any way. I have spent sooooo much time designing the pattern and test fitting that I am really looking forward to cutting into some real denim.

Time to roll out the good stuff!

Men’s Jeans Sloper and Pattern

I decided I wanted to start from scratch and make my own jeans pattern after not being completely happy with the results of the Burda 7733. I’ve also realized that this hobby is not just about sewing for me, but rather the entire process of making a garment from start to finish. That process includes designing/drafting my own patterns, picking out the fabric, sourcing notions, etc., and then the sewing. While sewing is obviously important and fun, it is only one of many steps involved in the process of creating a garment…and I want to do it ALL!

I didn’t really know anything about pattern making, but after scouring the internet for resources, I eventually settled on a book called The Practical Guide to Patternmaking for Fashion Designers: Menswear by Lori A. Knowles. It is a great resource for anyone wanting to make menswear, and was essential for helping me to make my own jeans pattern.

The first step in the pattern making process was using measurements taken directly from my body to draft a lower body sloper. I learned that a sloper is a very basic pattern, without any pockets or details, that provides a general shape and starting point for creating more “stylized” and finished patterns. From the sloper, you can draft actual pattern peices creating any style you want. It is a building block of sorts that can be used over and over.

mens jeans sloper 1

I needed an assortment of curves and rulers to draft the lower body sloper. It felt like a geometry project from high school at first.

mens jeans sloper 2

Here is the finished sloper pattern before I cut it out. I had to tape it to a glass door to be able to see the lines. The lower body back is on the left side, and the lower body front is on the right. From here, I cut out the front and back pieces in muslin for a test fit.

As I mentioned above, the jeans sloper has no pockets, yoke, or any details. It is just the fronts and backs sewn together to make sure I took proper measurements and that the basic shape and fit is correct.

My sloper fit great and I didn’t need to modify it to begin creating the jeans pattern. The book gives instructions for turning the sloper into a pattern, showing where to modify specific points on the sloper to create individual pattern pieces including pockets, yoke, waistband, fly, etc. I used these instructions as a starting point, but completely altered the shape and measurements to suit the style I was looking for. I wanted a somewhat slim fitting, straight leg, five pocket jean. The “straight leg” version in the book seemed more like a tapered leg to me so I changed the shape of the leg. I also changed the shape of the yoke, back pockets, front pockets, position of the crotch point, and the fly, arriving at my final pattern. The pattern in the book called for a zipper fly, but I decided that I was going to learn how to construct a button fly instead.

Once all of the pattern pieces were complete, I had to add seam allowance to all of the individual pieces. I used 3/4″ seam allowance for any areas where I would be doing a flat-felled seam, and 5/8″ everywhere else. These allowances are probably a bit big for muslin, but when I start using real denim, I want the flexibility to work with a bigger allowance.

I drafted all of the pattern pieces in tracing paper. Here is a picture of my final pattern. At this point, I hadn’t finished the fly so those pieces are not shown.

mens jeans pattern

The next step is to cut out and sew this pattern in muslin to see if everything goes together properly, and to check the fit again. Pattern drafting was actually quite enjoyable. I feel like it is the perfect right and left  brain collaboration, using geometry/math to achieve something more creative.

First Muslin Pair of “Jeans”

I figured that the best way to learn how to make a pair jeans was to start with a commercial pattern. I chose Burda 7733 mainly because it was one of only two patterns that I could easily find, and it seemed to have a more “modern” cut than the other pattern I saw. After completing the pattern with muslin though, I realized that I probably would have liked the fit of the Kwik Sew 3504 better. I can’t really say, however, because in trying to figure out which size to cut (Burda uses European sizing) I ended up cutting the pattern in too small of a size for me to actually try on. I’m a fairly skinny guy, usually wearing a 30-32 inch waist, and this practice pair would have fit like a blood restricting skinny jean, if I could have gotten them on at all.

The pictures aren’t the greatest quality and the muslin definitely needs to be ironed, but you get the idea.

It seems like the back pockets are positioned a little too low.

After examining lots of pictures online, and studying a few pairs of jeans in my closet, I decided that there is a lot I would change about this pattern. Starting with the back pockets, I would alter the shape and placement. As I mentioned above, I couldn’t actually try these on, but judging from the picture on the pattern envelope, the back pockets fall below the butt area onto the hamstring, which is too low for my taste.

As far as the front pockets go, I’ve never seen front pockets constructed with the same method this pattern uses. Even with my limited sewing knowledge, I think there are better/cleaner ways to make front pockets that will be stronger and more durable.

The last major change I would make is to the fly. I’ve decided that I want to try and learn how to make a button fly rather than a zipper. I went ahead and put in the zipper fly here because that is what the pattern called for, but my next practice pair will have a button fly.

Depending on how you like your jeans to fit and look, this pattern might be just what you are looking for. For me, it was a great way to get some much needed sewing practice, and it helped me to figure out what I want to do with future pairs of jeans.

Selvedge Denim

I’ve become obsessed with making my own pair of jeans. Why? I, like many people, spend about 95% of my waking hours wearing jeans. If you are going to spend that much of your life wearing one thing, it should be absolutely perfect.

While researching jeans construction techniques, I randomly discovered a little thing called selvedge denim (some people spell it selvage), and I have to say that I will never look at denim the same way again. For those who know what it is, you probably understand, for those who don’t, let me shed a little light. Most fabric has a selvedge edge, but with denim, the word selvedge has a special meaning. This Wikipedia entry explains it best.

I think the key with selvedge denim is that it is woven on old shuttle looms. Supposedly this creates a tighter, stronger weave since the cross thread is one continuous thread. On modern looms the cross threads are made up of individual threads, which can unravel more easily. In addition, I love that the old style looms produce denim with small inconsistencies, adding to the character of the finished fabric.

You can see the selvedge on these samples I ordered.

Denim mills used different colors of thread on the selvedge to distinguish between different brands. Levi’s used a red line, Lee used a green line, and Wrangler used a yellow line.

When I make my pair of jeans, I will definitely be using selvedge denim. Before I even think about cutting into high quality denim though, I have a lot to learn. I am going to start by sewing a practice pair using a pre-made pattern and muslin. Getting a feel for the basic pieces and shapes that go into producing a completed pair of jeans will be key to eventually creating my own custom pattern.

I love the history (which I need to learn more about) associated with denim. While jeans are a distinctly American garment, they are loved all over the world. I can’t wait to get going on my first pair!

Buttonless Button Down Shirt

Having never made a shirt, I thought the hardest part might be the sleeves, but I was wrong. The collar turned out to be the most difficult part and was nearly impossible to attach to the shirt. It literally took me ten or fifteen attempts at pinning, unpinning, repinning, basting, unpinning, unbasting, pinning and then re-basting again to finally get it right. That’s a lot of pins, some seriously soar, pin-pricked fingers, and more than a few swear words. But I persevered and eventually showed the collar who is boss.

The collar itself actually turned out quite nice for having never made one before.

Preparing the interfacing for the collar and the neckband.

As the title suggests, this is a buttonless ‘button down shirt.’ I still haven’t found the manual for the sewing machine and am beginning to think that I just need to order another one. Attempting button holes without it seems a little daunting at this point in my sewing ‘career.’

Overall the shirt was a great practice piece. I used McCall’s pattern #2447, which is the same package that The Vest came in. The cut is a bit loose and baggy, but otherwise it fits. Here is a picture of the “finished” shirt without buttons.

Pocket close up.

Back yoke.


The Vest

I wanted to take things up a few notches from the apron for my next project. It’s not that the apron was necessarily easy for a beginner, but let’s face it, there are really only three main pieces, which all lay flat on each other. I needed something complicated, something with armholes! I knew my limits and wasn’t about to try making sleeves for the first time. Since I’m not really a toga kind of guy, I decided to try making a vest. I used McCalls pattern 2447. I feel that the style of the pattern is a little dated, which is the case for almost all patterns for men’s clothing. Trying to find patterns for garments that I would actually wear is frustrating and next to impossible, but eventually I want to be designing/making my own patterns anyway.

Unless you count the polar fleece version I wore in middle school, (yikes…!) I’ve never worn a vest. And come to think of it, I definitely won’t be wearing this one either (note the masculine floral lining [with a hint of sarcasm] among other problems). I left off the buttons for now. We misplaced the manual for the sewing machine, which has the instructions for the button hole settings.


My wife had the fabric for the lining laying around and I figured that this was just for practice anyway, so why not use it. This stuff was REALLY hard to work with. I think it is some sort of polyester blend that makes it difficult to mark, fold, sew, and look at for that matter. The front of the vest is muslin of course.


I had to learn how to hand sew a slip stitch to close up the side.


Now that the vest battle is over, I think I’m ready to tackle sleeves. I have a pattern for a men’s long sleeve button down shirt that is next on the chopping block.

The Apron

Originally, I had the wild idea that my first “real” project would be a tailored suit jacket. How hard can it be right…? Let’s just say that after taking one look at the pattern pieces for the jacket, I decided that I would need to attempt something much simpler for my first project. Basically I needed a pattern with mostly straight lines and a relatively small number of pieces.

Luckily my wife had a pattern for an apron that she made a while back. A muslin apron is definitely a long way from a jacket, but you got to start somewhere.


I was getting ready to cut my very first pattern in this picture. Could they make pattern paper any thinner? I thought it would disintegrate in my hands.


This is Kalypso, otherwise known as “The Kittaih!,” and she wants to learn how to make an apron too.


Pinning my first pocket.


The finished pocket and neck strap.


Tada! Finished apron. I couldn’t be happier with the way this turned out. Granted, it was a pretty easy project, but I literally went straight from the practice stitching here: Day One to the apron.

I’m still not ready to attempt anything close to a jacket yet, but look forward to whatever is next.

Day One

Photo of my first stitches.

Photo of my first stitches.

So really, I didn’t know anything about sewing when I took this picture of my very first attempt at some basic stitching. My wife, who is a phenomenal sewer, decided she would teach me some basics about the sewing machine. My first “lesson” went something like this:

Wife: “Taylor, let me show you how to wind the bobbin and thread the machine.”

Me: “Wind the what?” “You have to thread the machine?” Then I got distracted by the stitching diagram, “Oooh, it can do a zig zag, whoa that’s cool.”

Needless to say, she is a great teacher. Once I finally got the bobbin wound and the machine threaded, I played around a bit with some different types of stitches.

Next up, my first real project.