Instructables
Let's make a simple, cheap, durable bifold wallet out of Tyvek (the housing wrap and express mail envelope material).

Please note: this is my first instructable.

 
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Step 1: Materials and Pattern

Materials: 6 x 14.5 inches Tyvek or fabric of your choice (duct tape, 1000 denier nylon, denim, rip-stop nylon, etc), 3 inches of elastic (almost anything will work), optional: zipper, velcro

You can either sew the wallet together (which I am doing), or tape it together with packing tape or duct tape or another suitable tape.

This is the pattern, all measurements in inches. No seam allowances are needed.

If this image is unreadable:
the main body is 6 x 7.5
the small flap is 0.75 x 2.5
the large flap is 2.5 x 4.5

Step 2: Construction Step 1: Cut Out Pattern

Place the above pattern on the right side (the side you want showing) of the fabric.

Cut out the perimeter. Do not cut the flaps off.

Step 3: Construction Step 2: Attach Elastic Band

Sew (or tape) the middle of the elastic to the skinny flap. This is going to be the card holder. OPTIONAL: sew velcro to the flap to keep the wallet closed.

Fold the flap along the dotted line (about 1/4 inch from the body of the wallet, depending on how many cards you carry) and sew the elastic to the body at the top and bottom of the elastic.

Step 4: Construction Step 3: Change Pocket

Fold the larger flap over. This is going to be the change pocket. This flap seems too long (it goes past the halfway point) because we are going to make accordion folds so that it expands when we put things in it. OPTIONAL: sew velcro to the flap to keep the wallet closed.

Make accordion folds at both sides of the flap. Sew them up. Finally, sew the bottom (you may not want to sew over the accordion folds - I did). The pocket is now complete. OPTIONAL: add a zipper to the top of it.

Step 5: Final Construction Step: Sew Up Sides

Fold the wallet in half and sew up the sides. Turn it over. Your wallet is complete.

awig21 hours ago

nice tutorial, thank you!

This is a truly practical thing to do with tyvek material. A wallet made out of tyvek material is a really clever idea. I think that going just one step further - by adding a snap fastener to the tyvek wallet - can make it even more convenient to use, because the added snap fastener prevents the wallet from opening up undesirably. I made my first tyvek wallet very recently, and added a fastener.

http://www.esnips.com/web/TyvekWalletWithSnapFastener
dynomighty5 years ago
Hey

Its great to see such enthusiasm around tyvek - looks like a design I posted a couple years ago. I posted instructions and a video here if anyone is interested.
www.instructables.com/id/Express-Mail-Envelope-tyvek-Wallet/

This video demonstrates how to make the Tyvek Envelope Wallet here:
http://www.youtube.com/watch?v=oQGJbP92NRI

Many years ago I was the original designer of the Tyvek Wallet called the "Mighty Wallet" which is now gaining popularity after years of marketing and hardwork. Its really cool to see this new trend in wallet design emerging into the limelight - THANKS!

You can see the Mighty Wallet on my website: www.dynomighty.com

You were one of the designers of Mighty Wallet! That's too awesome!
Have you tried using rip-stop nylon? Works a treat. Can be free if you live anywhere near a sailmaker, kitemaker or similar. We managed to get bin bags full of the stuff - Now have to try and find the money and cards to fill all the wallets we could make!
where do u get tyvek?
goldscott (author)  Zaphod Beeblebrox4 years ago
You can get 11x17 inch tyvek envelopes from FedEx and USPS, as well as UPS.

Large rolls of tyvek are used for housing wrap, but one of those rolls is probably pretty expensive.
jumpertoad4 years ago
cool
berserk5 years ago
How durable is tyvek for this application? I had just a plastic sleeve for my licence and stuff but it's wearing out. It has lasted for several years, so how well does this hold up?
goldscott (author)  berserk5 years ago
I've had the wallet for about two months now, and so far so good. No rips or tears; looks the same as the day I made it. I noticed the Tyvek is getting a bit "softer," sort of like an old dollar bill. I like the feeling, though. I would assume that the Tyvek will easily hold up for a few years. I know those plastic sleeves generally rip apart at the seams; I don't think Tyvek will have that problem, especially if you sew it.