So do you want to make a mini Maillot Jaune for your own budding cyclist? I used the Flashback Skinny Tee from Made by Rae as a starting point and made a few adjustments to get a cycling jersey. The changes include adding elasticated pockets on the back, a full length zip on the front, elasticated waistband and sleeves and adding a collar in the same material as the T-shirt. Rae just released it in sizes 6-14 too so you could make it for older children as well.
I originally wrote the instructions for this here on my blog Craftstorming. Sky also gained a new sponsor :)
Step 1: Materials and Tips
Knit fabric (about ½ yard for 4T, I used this yellow lycra with 4 way stretch but any stretchy knit with good recovery would work well)
1 open ended (separating) zip (size 14” for 2T, 16” for 4T)
Lightweight fusible interfacing
Sewing machine (I also used my serger but you don’t need one)
Water soluble basting tape (I love this stuff)
Good quality sharp pins
Rotary cutter and 24″ quilting ruler
If you are using a lycra fabric then I have a few tips. It is the first time I have sewn with this fabric and I am far from an expert but hopefully I can stop you making the same mistakes that I did…
1. Use a ball point or stretch needle
2. Pins are much more likely to leave marks or snag so make sure you only use really sharp ones
3. Be extra careful with your seam ripper as the fabric tears very easily
4. Don’t use a really hot iron and test a scrap bit of fabric first
5. Don’t skip the interfacing – your zip will look a lot better for it
6. Though the fabric has 4 way stretch there is one direction that is more stretch than the other – cut your pattern pieces so the stretchiest direction goes across the body
7. I found there was a subtle difference in the colour of two sides of the fabric so make sure you’re consistent. On the plus side it was fairly easy to tell as it curls obviously to the right side. It still didn’t stop me attaching one sleeve the wrong way though.
Step 2: 1. Cut Out Your Pattern Pieces
You also need to cut out an extra piece for the back pockets. I used the main pattern piece and cut the shape from the bottom to 7” up for the 4T jersey. When deciding how high you want your pocket piece remember that you will lose almost 1.5” of the height to seams, so cutting 7” high gives you 5.5” high pockets.
Also, cut two pieces of interfacing that are the height of the middle of your front pieces by 1” wide. Iron these onto the wrong size of your front pieces.
We will cut the collar (and collar interfacing) in a later step. You will now have the pieces show in the second photo.
Step 3: 2. Mark Your Pockets
Start with your back pocket piece and use tailor’s chalk to mark on the location of the pockets. First mark on ½” from each side seam for the seam allowance. Then measure the distance between these two markings and divide by the number of pockets you want. Make a mark that distance from each of the two seam allowance markings.
Next draw a line down from each of the pocket markings. You will sew here to divide up the pockets. Here is my pocket piece, hopefully you can see the chalk lines.
Repeat this process with the main back piece so the markings are in exactly the same places.
Step 4: 3. Add Elastic
Sew the seam with a 3/8” seam allowance. Use a stretch stitch if you have one, if not then I’d recommend a zig zag stitch as the pockets will probably get stretched a lot.
Cut a piece of ¼” elastic that measures about 1.5” less than top of the pocket piece. Use a bodkin or safety pin to pull the elastic through the casing.
When the tail end of the elastic is level with the edge of the pocket piece stitch it into place about ¼” from the edge.
Pull the other end of the elastic through. At this point you can judge if you want to make the elastic shorter to get stretchier pockets. Once you’re happy with the length stitch the elastic into place as before.
Step 5: 4. Attach the Pocket Piece
I found this fabric had a tendency to slip when I was sewing two pieces together across the width (despite using lots of pins), although it was fine in the other direction. If using a sewing machine I would recommend joining the two pieces with water soluble basting tape before sewing across the bottom. Don’t worry if you get a wavy effect on the bottom seam as the elasticated casing we add later will hide this.
I also serged the bottom of the fronts of the shirts so they would be the same length and have the same finish. This is optional if you’ve used a sewing machine.
Pin the pocket and back pieces together at the pocket markings. Stitch down the elastic at the top securely then sew down the lines you marked to create the pockets.
Step 6: 5. Sew the Shoulder Seams
Step 7: 6. Cut and Attach Collar Piece
Cut your collar piece to be this width by 3″. This will give you a collar that is 1 and 1/8 inches high. If you would like a different height collar adjust your measurement accordingly – you will need to cut you piece with a height of 2 x (desired collar height + 3/8″).
I measured the 4T size as 16″ wide, although I added an inch just to be safe and ended up needing it, so my piece was 17″ by 3″. Cut a piece of lightweight fusible interfacing the same width but by 2¼”. This means that the edges will not have interfacing and reduces some bulk in the collar seam.
Iron the interfacing onto the wrong side of the collar piece, leaving 3/8″ of the collar uncovered at the top and bottom. Pin the edge of the collar piece to the edge of the T-shirt, right sides together. Sew with a 3/8″ seam using a regular straight stitch.
Flip the collar upwards and press seam allowances upwards towards the top of the collar.
Step 8: 7. Add Any Decoration
I found it easier to make sure my split design would line up this way. I also tried adding the zip with the seam closed like this too but found I couldn’t line up the edge of the fabric as close to the teeth as I wanted on both sides.
Press the seam allowances open and add your design to the right side.
I used Inkscape to design my cutting file and Make The Cut to cut it out of heat transfer with my Black Cat Lynx. I layered the heat transfer to match the Team Sky design.
If you’re not adding any decoration or want to add it once you’ve finished they jersey then just press the middle of each front piece half an inch to the wrong sides and move onto the next step.
Step 9: 8. Zip
Now we need to check how long your zip needs to be. Measure the length of the middle from the bottom to the collar seam (not the top of the collar), add 1 and 1/8 inches for the height of the collar (or whatever measurement you chose in step 6 then deduct ½” (for the hem at the bottom). For the 4T size I needed my zip to be about 15″ and for the 2T I needed it to be 13″. Mark the measurement on your zip with chalk or a disappearing fabric pen, then lie the zip in place on your top to check.
You can see in the second photo that I’ve place the zip ½” from the bottom. I then folded my collar over to the height it will be after folding down so the top of it now lines up with the collar seam. My pen mark is level with the top of the collar. You will actually need your zip to be a little bit longer than this so you double it over at the top to prevent the zip pull coming off.
Take your zip away from the top and make a further mark about 1″ above the previous one.
Move the zip pull down below these marks and cut across the top marks.
I would recommend putting a temporary stop in place by using a safety pin. This will prevent you accidentally pulling the zip pull of (yes, I did this).
Pin or use water soluble basting tape to attach one side of the zip to the top. Starting at the bottom attach in place and pull the top taut as you work your way up. This will prevent the fabric bunching up when you sew your zip in place. When you get to the top attach up to the middle of the collar then leave the rest. The interfacing you applied earlier means that you can’t stretch the fabric too far.
Repeat on the other side, making sure you line up both sides at the bottom, at the collar and your design if you have one.
Now open the zip fully. We are going to sort out the top of the zip. This is the hardest part of the tutorial to explain but hopefully the penultimate photo will help.
You need to flip over the collar so the edge you can see lines up with the collar seam. Pin this into place. Arrange the top as close to the zip teeth as possible on the front side. On the reverse side though you need to angle the zip inwards. If you don’t do this and fold it straight over you will find that the teeth make it really difficult to close the zip all the way to the top. Pin this into place and do the same on the other side.
Do the zip up again and double check that everything lines up. Use your zipper foot and a straight stitch to sew your zip onto the top. Start at the top and backstitch a couple of stitches. I found I had to pull it through by hand initially to move over the teeth at the back of the top but once you get past this the rest is easy.
Repeat on the other side and your zip is finished.
Step 10: 9. Finish Collar
Sew along the collar about 1/16″ from the collar seam.
Step 11: 10. Attach Sleeves and Sew Side Seams
Step 12: 11. Waistband Hem
Measure the waistband and cut elastic about 2” shorter. Feed this through using a safety pin. Stitch the first side in place then check you are happy with the length before stitching the other end in place.
Tip: to avoid accidentally pulling the trailing end of the elastic through and having to start again place a safety pin on both ends.
Step 13: 12. Hem the Sleeves
Measure the opening of the sleeve and cut elastic about this length. Feed this through with a safety pin until it can be pulled through the other side. Overlap the ends by about ½”, check you’re happy with this and it won’t be too tight for your little one’s arm. Sew the two ends of the elastic together.
Sew the opening of the casing closed and repeat for the other sleeve.