Step 1: Gather Materials and Tools
-1/4 yard durable fabric
-1/4 yard clear vinyl
-2 yards of 3/4 inch binding tape
-4" x 8.5" stiff cardboard
For this project you'll need the following tools:
-Fabric marking pencil
-Felt tip marker
-Scissors or rotary cutter
-Sewing machine (dual needle is best for binding tape)
-(Recommended) Binder for sewing machine
-(Recommended) Hot knife and cutting surface for finishing binding tape
-(Optional) 1" circle punch from scrapbook store
-(Optional) ball point pen for notes
Materials and tools pictured here are available from ParaGear:
-Fabric: 500 denier black Cordura Item W9345
-Binding Tape Item W9850
-Vinyl medium weight from Wal-Mart
-Binder for 3/4" Binding tape Item S7460
-Hot knife is a Wood Burning tool similar to this one and purchased at Wal-Mart
Step 2: (Optional) Make Templates
1) Back cover: 4.5" x 9.25"
2) Inner pocket: 3.5" x 8.25"/5" (see picture for slant)
3) Outer ID pocket: 3.5" x 2.75"
4) Inner credit card pocket: 2.5" x 4.5"
I used an empty Diet Coke case for the cardboard to make these templates.
On the 3) Outer ID pocket template, mark (but do not cut) a semi-circle off set by 0.25". This provides access to the ID. The offset is because one side of this pocket will be covered by the binding tape.
Step 3: Mark and Cut Material
From the fabric
-three (3) of the Back Cover (template 1)
From the vinyl
-one (1) of the Back Cover (template 1)
-one (1) of the Inner Pocket (template 2)
-one (1) of the Outer ID pocket (template 3)
-two (2) of the Inner Credit Card Pocket (template 4)
From the stiff cardboard
- one (1) rectangle 4" x 8.5"
Use the circle punch to cut out the semi-circle from the Outer ID pocket. It doesn't have to be exactly a semi-circle. Try some different depths of the cut to determine what works best for you.
Note: Templates #1 and #4 are the same width. Templates #2 and #3 are the same width. Trim a 4.5" strip from the vinyl and all pieces can be trimmed from this strip. If you're making multiple jackets, cut one strip 4.5" and another 3.5". Cut out the needed pieces from these strips.
Step 4: Build the Inside Pockets
-Start with one of the fabric back covers and the two inner credit card pockets.
-Position one vinyl pocket along the bottom of the cover
-Sew the top of the vinyl
-Fold the vinyl up to form the middle pocket
-Sew down left side of the pocket to hold it in place
-Place the second vinyl pocket along the bottom of the cover
-Sew down left side
-Sew across bottom to secure vinyl in place
Folding the first piece of vinyl up to create the middle pocket places the stitches on the inside of the pocket. It also prevents an edge of the middle pocket from interfering with taking things out of the bottom pocket.
The right edge does not have to be smooth. It will be trimmed down later.
Step 5: Prepare Outer Covers
- Sandwich the vinyl cover between the remaining fabric covers
- Stitch along the right long side of the sandwich
- Fold the fabric to the right, away from the vinyl
- Place the cardboard stiffener inside the fabric covers
- Stitch down the remaining three sides of the back cover to secure the cardboard on the inside.
The vinyl can be slippery and make it difficult to sew into the center of the two fabric covers. Use clips or hemostats to hold the pieces together. You don't want to us pins because the pinholes will be left in the vinyl and look poor on the finished product.
The cardboard stiffener should be smaller than the covers so the fabric can be stitched together. If it doesn't fit well, you can sew through the cardboard without difficulty. This may make it harder to attach the binding tape later.
Step 6: Finish Front Cover
1) Align the Outer ID pocket at the lower right corner of the front cover. This pocket is on the outside. In the picture it is on top.
2) Sew down the left side of the Outer ID Pocket. Remember to lock the stitches at the top of the pocket.
3) Align the Inner Pocket to the same lower corner of the front cover, but on the inside. The picture below has the pocket on top. Place the long edge along the outer edge of the front cover as indicated in the picture.
4) Stitch down the outer edge and bottom of this pocket.
Step 7: Configure Sewing Machine for Binding Tape
I tried to minimize the reconfiguration steps, but you will have to configure for binding tape twice. having a separate machine dedicated to binding tape is the best solution, but also the most expensive.
Using a binder with your sewing machine is not required, but makes attaching the binding tape much easier. A binder can be purchased from ParaGear. If you can't screw it down, you can temporarily tape it to the sewing machine.
If you're not familiar with using a binder ask your local sewing machine store for advice. The hardest part is making 90 degree corners. To practice I made a lot of coasters for friends and family. That was square scraps of material that I added a binding to. It isn't glamorous, but a good way to practice corners.
Step 8: Add Binding to Inside Pockets
Then remove the binder from your sewing machine.
Step 9: Final Assemby
- Stitch the top, right, and bottom of the inside pocket to the back cover. The right side of the inside pocket will extend off the edge of the back cover.
- Trim excess
This is a good time to clean up all of the edges of the project. If you did not get some of the parts aligned well, trim them down. This creates smooth edges that are easier to bind and cover the assembly stitches.
Step 10: Reattach Binder
Step 11: Attach Final Binding
I work with the outside facing up. If I'm going to botch the corners, it will be the bottom side, so I make this the inside of the project.
Think about which corner to start at. Where you start will be where you finish and there will be a different edge, sometimes sharper than the bound corners. These pictures show the bottom back corner is the start-finish point.
Step 12: Trim Excess Binding
Congratulations! You've completed your Airline Ticket Jacket.
Fold the cover carefully. It will take a few uses before the vinyl creases properly. Depending on the thickness of the cardboard used, the jacket will lose its stiffness. It will still protect your tickets, but you may want to consider building a new jacket.