A customer wanted an insulated pouch made for his iphone 5 for when he was skiing during long periods in the frigid weather. He provided the materials and I made a mock up of his phone using cardboard and tape, with the dimensions found online.
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Step 1: Materials List
He pre-purchased a leather pouch for its opening hardware, the hinged type that opens when you squeeze the ends.
Felt, vinyl(or leather) and silver insulator material
And the phone or mock-up to do "fittings"
If you don't have access to a sewing machine, you could certainly do this with duct tape and cold-weather glue.
Step 2: Sewing the Lining
Soft felt is used for the lining.
Allow a bit of ease for the phone to slide into, then sew your first seam.
Press seam open, then chalk the bottom seam. Stitch that.
Step 3: Insulation
This insulation does allow signal to come though.
Put phone in felt pouch, then wrap insulation around that, determining best fit.
Cut to size and tape together side and bottom seams with duct tape.
Step 4: Outer Layer
Cut vinyl to approximate dimensions, then wrap around insulator pouch to determine best fit.
Mark seam line and stitch.
Press seams open using cotton as a barrier.
Turn right-side out and press again.
Step 5: Attaching Pouch to Opening Hardware
Turn vinyl pouch inside out.
As shown in picture, slide opener inside.
Adjust seam of pouch, if needed, to fit opener. I decreased the top a little bit to fit snugly.
Carefully stitch through thicknesses, keeping edges aligned.
Check that all seam allowances were captured sufficiently and turn right-side out to check work.
Step 6: Attaching Lining
Turn vinyl pouch inside out again.
Turn felt liner inside out, so that seam allowances are on inside(see 2nd pic)
Feed liner inside, as shown, and sew all three layers together.
Pull vinyl layer right-side out, then push felt liner inside.
Step 7: Adding the Insulation
Feed/shimmy insulation pouch inside of vinyl, outside of felt.
You'll need to put the phone inside to help with this process, to ensure that the insulation pouch is all the way in.
Stitch bottom, trim any excess.
Step 8: Finished Pouch
Works great. Looks great.
Time to hit the slopes!