Tutorial: Sew a Boxy Zippered Pouch; the perfect pencil case!

Tutorial:  Sew a Boxy Zippered Pouch; the perfect pencil case!

If your household is like mine, you must be in full back-to-school mode!  This year I wanted to make my son his own pencil case…let’s be honest, I’m just trying to find a way for him to get excited about his pencil and hopefully not loose as many this year…lol!  This case sews up so quickly and the best part is, they are super cute and you can make your own for your purse, to hold your cosmetics, or anything!!

In this tutorial, I walk you through the step-by-step process of creating your own cute zippered pouch that is both practical and professional. From gathering supplies to adding the finishing touches, get ready to elevate your sewing skills and showcase your craftsmanship with confidence. Let's get started!

Let’s talk about fabric choices!

Before we dive into the full supply list, let’s take a moment to talk about fabric choices for your pouch.  For most projects, I tend to use quilting cotton - but this one is a little different.  First, think about what you plan to use your case for?  A cute cosmetic pouch - some quilted cotton fabric would look cute and hold up!  But, for a pencil case for my 3rd-grader, I’ll be using canvas!! 

There are so many options on the market now for canvas.  Many fabric lines release a few prints in canvas, and many quilt shops carry them in their bag-making sections.  For my pouches, I decided to splurge and I purchased a few fat quarters from Spoonflower.  I selected some of my favorite designs and ordered the Linen Cotton Canvas.  I also uploaded some of my son’s artwork from when he was younger to use for the lining of his pouch. 

Now, I’m generally not a pre-washer when it comes to my fabric — for quilts I subscribe to the crinklier the better!  This project though, is an exception for me for a couple reasons.  First, because I ordered from Spoonflower, I know my fabrics were digitally printed when I ordered them and I’m a bit nervous about the dye running in the finished product.  Second, I don’t want to risk any possible shrinkage or distortion of the pouch when it is completed.  Start by washing and ironing it to ensure a smooth and clean surface for your project. 

Once your fabric is prepped and ready to go, you can move on to cutting out the necessary pieces for your pouch and gathering the remaining supplies.

Gathering supplies

To bring your vision to life, you will need:

• Exterior Fabric:  (2) 5 1/2” x 11” rectangles
• Interior Fabric:  (2) 5 1/2” x 11” rectangles
• Optional Zipper Tab:  (1) 3” x 4” rectangle
• (1) 12” Zipper
• Zipper Foot for your sewing machine
• Everyday Foot for your sewing machine (whichever foot you tend to use when sewing)
• Lightweight fusible interfacing:  (2) 5 1/2” x 11” rectangles
• Notions such as coordinating thread, scissors, pins, and your sewing machine

By having all your supplies ready and organized, you'll set yourself up for success!

Let’s start sewing!!

Begin by attaching the fusible interfacing to the wrong side of your exterior fabric pieces.  This step is optional, but will add stability to your finished product.

Next, prepare the zipper tab if you are using one.  Begin by folding the fabric lengthwise and pressing.  Then, unfold and fold the two sides in towards the center line, then fold along the center line again and press.  Sew 1/4” from both sides of the strip.  Fold in half widthwise and press.  If you have binding clips, clip the tab to help hold the shape and set it aside.

Next, attach the zipper to the first side of your fabric.  Make sure you switch to use the zipper foot of your sewing machine for these next few steps!  Begin by placing the zipper face up, lay one exterior fabrics piece, right side down, on top of the zipper and line up the edges; clip or pin in place.  Then, place one interior lining piece on the other side of the zipper with right side towards the exterior fabric, lining up all edges; clip or pin in place.  Then, sew using a 1/4” seam.  Press the fabrics away from the zipper, again lining up the edges and top stitch.

Repeat these steps with the other side.

Next, fold the pouch so that right sides of the exterior and right sides of the lining are touching.  Again, using a 1/4” seam, sew the bottom seams on both sides. 

Once sewn, you will want to press the seams open to make the next steps easier with less bulk.  To do so, you’ll need to move the seam in a position to press open noting that it will be over part of the bag.

This next steps can be the trickiest part of the whole process.  You can watch the video below for an example.  Before starting, make sure that your zipper is secure and will not fall off when fully open.  If you are using zipper tape like I am, make sure you use a pin or binder clip to secure the zipper pull.

Then, open the zipper fully.  With one hand on the edge of the open zipper side, please your other hand through the middle.  Grab the side with the zipper pull and bring it through the middle to create a tube with the right side of the lining fabric on the outside and the right side of the exterior fabric on the inside.  Close the zipper about half way.

 Fold the pouch in half lining up the center of the zipper with the bottom seams.  Clip or pin at the edges to avoid shifting and make sure the zipper pull is in the middle of the pouch. 

Slip in the optional zipper tab at this point between the zipper and the pouch with the fold side in and the raw edges of the zipper tab lined up with the raw edges of the pouch.  Then, sew using a 1/4” seam along the top and bottom raw edges to close up the pouch.  Trim off any excess zipper that overhangs the ends of the pouch.

Now its time to box those corners!  Using a marking tool and a ruler, mark a line 1 1/4” in from each of the four corners and cut out the square that you marked.

Expand the pouch and line up the two sides of one of the boxy corner openings.  Pinch together and sew closed using a 1/8” seam.  I recommend back stitching at the beginning, end and over the zipper.  Repeat with the remaining three corners.  If you’d like, you can use a piece of scrap binding to cover the raw edges of this seam.  I opted to skip this step, as I am okay with the raw edges inside this pouch.

Finally, turn the pouch right side out through the zipper opening.  Make sure to use a point turner at all of the corners to expand the pouch fully and enjoy your new pouch!!!

These pouches come together fast and I can see them becoming addicting!  You can play around with the size of the pieces cut to make a larger or smaller pouch, and play around with the types of fabrics used to make one that’s perfectly you!  These pouches also make great gifts for fiends and family!