How to Create a Special Zipper Bag Easily Out of Old Jeans

It's currently June 17, 2025. This project is a fantastic way to upcycle old jeans into something practical and stylish! Making a zippered bag from old jeans is not only eco-friendly but also results in a unique, durable item. Here's a detailed guide on how to create a special zipper bag easily, focusing on simplicity and using the unique features of jeans.

How to Create a Special Zipper Bag Easily Out of Old Jeans

This guide aims for ease, leveraging existing jean features like seams and pockets. We'll make a simple flat pouch or a small tote, suitable for toiletries, art supplies, or a small project bag.

I. Planning Your Bag & Materials:

Before you cut, decide on the size and shape of your bag. This will determine which parts of the jeans you use.

Bag Types:

• Simple Flat Pouch: Uses two flat pieces of denim.
• Pouch with Depth: Achieved by boxing corners, similar to a tote.
• Small Tote/Project Bag: Larger, uses more of the jean leg, possibly incorporating the waistband for structure.

Materials You'll Need:

1. Old Jeans: 1 pair (or more, depending on bag size and design). Look for jeans with good, sturdy denim and interesting pocket designs.
2. Zipper: A nylon coil zipper is easiest to sew.
   • Length: At least 2 inches (5 cm) longer than the top width of your planned bag. (e.g., 8-12 inches / 20-30 cm).
3. Lining Fabric (Optional but Recommended): A lightweight cotton or poly-cotton fabric. About 1/2 yard (0.5 meters) for a medium bag.
4. Interfacing (Optional): Light to medium-weight fusible interfacing if your denim is very soft or you want more structure.
5. Thread: All-purpose polyester thread that matches or contrasts your denim.
6. Basic Sewing Supplies:
   • Sewing Machine (with a strong needle, e.g., denim 90/14 or 100/16)
   • Denim-specific or heavy-duty needle (important for thick seams!)
   • Fabric Shears or Rotary Cutter and Mat
   • Quilting Ruler
   • Fabric Chalk or Mark-B-Gone Pen
   • Plenty of Pins or Wonder Clips (especially useful for thick denim)
   • Iron and Ironing Board
   • Zipper Foot for your sewing machine
   • Seam Ripper (denim can be unforgiving!)

II. Disassembling & Preparing Your Jeans:

This is where you get to decide what features to keep!

1. Wash and Dry Jeans: Ensure they are clean and pre-shrunk.
2. Cut Off Legs: Lay jeans flat. Cut off the legs just below the crotch area. You can save the waistband, fly, and top pockets for other projects, or incorporate them into a larger bag.
3. Open Up Leg Seams (Optional but Recommended): For flatter pieces of fabric, use your seam ripper to carefully open up the inseam (the seam on the inside of the leg). This gives you larger, flatter panels to work with. The outer side seam (usually with topstitching) can be kept intact for a decorative element.
4. Press Flat: Iron the denim pieces flat, especially if you've opened seams.

III. Designing & Cutting Your Bag Pieces:

This is where the "special" comes in, by using the jean's features.

Considerations:

• Back Pockets: One of the easiest ways to make a "special" bag is to use the back pocket of the jeans as one side of your bag. Cut around it, leaving seam allowances.
• Hems: You can use the original hem of the jeans as the top or bottom edge of your bag to save sewing time and add a decorative touch.
• Fade/Wear: Embrace the natural wear and tear for character!

Example Bag Design (Simple Pouch with a Back Pocket):

Let's assume a finished bag size of approximately 9" wide x 6" tall (23 cm x 15 cm). We'll use a 1/2" (1.27 cm) seam allowance.

1. Main Exterior Panels (Denim):
   • Front Panel: Carefully cut out one back pocket from the jeans, leaving approximately 1/2" (1.27 cm) seam allowance around its top, bottom, and sides. The pocket itself will be the front of your bag. Alternatively, cut a flat denim rectangle of 10" wide x 7" high (25.5 cm x 18 cm).
   • Back Panel: Cut one rectangle of flat denim, 10" wide x 7" high (25.5 cm x 18 cm). If you want two pockets, cut a second back pocket.
2. Lining Panels (Lining Fabric):
   • Cut two rectangles, 10" wide x 7" high (25.5 cm x 18 cm).
3. Interfacing (Optional):
   • If using, cut two pieces slightly smaller than your main denim panels (e.g., 9.5" x 6.5" / 24 cm x 16.5 cm) to avoid bulk in the seams. Fuse to the wrong side of your denim panels.

IV. Sewing Your Zipper Bag:

Important Note on Denim: Denim is thick!

• Use a denim-specific or heavy-duty needle (size 90/14 or 100/16).
• Use Wonder Clips instead of pins where seams are very thick.
• Go slowly over bulky seams, hand-cranking if necessary.
• Increase your stitch length slightly (e.g., 2.8 - 3.2 mm) for topstitching and general construction to prevent skipped stitches and accommodate the fabric.

Steps:

1. Prepare Zipper:

   • If your zipper is much longer than your bag width, you can shorten it. Stitch a line across the zipper teeth about 1" (2.5 cm) from where you want the new end to be. Trim the excess zipper tape.
   • Optional: Create small fabric tabs for the ends of your zipper. Cut two small denim rectangles (e.g., 1.5" x 2" / 4 cm x 5 cm). Fold them in half lengthwise and press. Sandwich each end of the zipper tape inside a folded tab and stitch securely. This gives a nice finish and makes it easier to sew.

2. Attach Zipper to Main Exterior Panels:

   • Lay one Main Exterior Denim Panel right side up.
   • Place your zipper right side down along the top edge of the denim panel. Align the top edge of the denim with the top edge of the zipper tape. Center the zipper horizontally.
   • Pin in place.
   • Attach your Zipper Foot to your sewing machine.
   • Sew along the zipper tape, close to the teeth (but not hitting them), using a 1/2" (1.27 cm) seam allowance. Backstitch at beginning and end.
   • Press the denim panel away from the zipper.
   • Topstitch: On the right side of the denim, topstitch very close to the zipper seam you just made (about 1/8" / 0.3 cm from the seam). This adds a professional finish and keeps the fabric flat.

3. Attach Zipper to Second Main Exterior Panel:

   • Take the second Main Exterior Denim Panel.
   • Place the unsewn side of the zipper right side down along the top edge of this second denim panel. Ensure the first denim panel is folded out of the way.
   • Align the top edge of the denim with the zipper tape. Pin.
   • Stitch using your zipper foot, 1/2" (1.27 cm) seam allowance. Backstitch.
   • Press the denim panel away from the zipper.
   • Topstitch: Topstitch this side as well, close to the zipper seam.

   Result: You now have your two exterior denim panels joined by the zipper.

4. Attach Zipper to Lining Panels (The "Burrito" Method for Encasement):

   • Lay the exterior piece (with zipper attached) flat, right side up.
   • Take one Lining Panel. Place it right side down on top of one of the denim panels, aligning its top edge with the same zipper edge you just sewed to the denim. The denim panel and the lining panel should sandwich the zipper.
   • Pin in place.
   • Using your zipper foot, sew along the seam you previously made, or very close to it, through the lining, zipper tape, and denim. This encases the zipper tape between the denim and the lining. Backstitch.
   • Press the lining away from the zipper.
   • Repeat for the other side: Take the second Lining Panel. Place it right side down on top of the other denim panel, aligning its top edge with the remaining unsewn side of the zipper. Pin and stitch.
   • Press the lining away from the zipper.

   Result: All four panels (2 denim, 2 lining) are now attached to the zipper, with the zipper tape neatly hidden between the layers.

5. Sew Side and Bottom Seams (The "Bag within a Bag" Method):

   • Open the zipper at least halfway! This is crucial for turning the bag later.
   • Separate Layers: Pull the two exterior denim panels so their right sides are together. Pin along the sides and bottom.
   • Pull the two lining panels so their right sides are together. Pin along the sides and bottom.
   • Stitch Exterior: Stitch the side and bottom seams of the exterior denim panels with a 1/2" (1.27 cm) seam allowance. Backstitch at beginning and end.
   • Stitch Lining: Stitch the side and bottom seams of the lining panels with a 1/2" (1.27 cm) seam allowance. Leave a 4-5 inch (10-12.5 cm) opening in the middle of the bottom seam of the lining. This is for turning the bag right side out. Backstitch at the start and end of the stitched sections of the bottom seam.
   • Press Seams Open: Press all your side and bottom seams open to reduce bulk, especially with denim.

6. Box the Corners (Optional, for Depth):

   • This step is for giving your bag a flat bottom. If you prefer a flat pouch, skip this step.
   • For both the exterior and lining bags: At each bottom corner, bring the side seam and the bottom seam together, aligning them perfectly. This creates a triangle.
   • Measure in from the tip of the triangle a distance equal to half of your desired bag depth. (e.g., for a 2" depth, measure 1 inch / 2.5 cm). Draw a straight line perpendicular to the seam.
   • Stitch along this line, backstitching securely.
   • Trim the excess fabric from the corner, leaving about a 1/2" (1.27 cm) seam allowance.
   • Repeat for all four corners (two exterior, two lining).

7. Final Assembly & Turning:

   • With the zipper still open halfway, and both the exterior and lining wrong side out:
   • Reach inside the lining through its bottom opening.
   • Place the exterior bag (right side out now) inside the lining bag (still wrong side out). The right sides of the lining and the exterior should be facing each other.
   • Align the side seams of the exterior and lining bags.
   • Carefully align the top raw edges of the exterior and lining fabric all around the zipper, ensuring the zipper is centered. Pin securely all around the top.
   • Stitch the Top: Using a 1/2" (1.27 cm) seam allowance, stitch all around the entire top edge of the bag. Go slowly, ensuring you catch all layers (lining, zipper tape, denim). Backstitch at beginning and end.
   • Clip & Trim: Trim the seam allowance at the top down to about 1/4" (0.6 cm) to reduce bulk. Clip any curves if necessary.

8. Turn Right Side Out & Finish:

   • Reach through the opening in the bottom of the lining.
   • Carefully pull the entire bag right side out through this opening. Take your time, push out corners, and get a good shape.
   • Close the Lining Opening: Press the raw edges of the opening in the lining under by 1/2" (1.27 cm). Stitch this opening closed by machine (very close to the folded edge) or by hand using an invisible ladder stitch for a cleaner finish.
   • Push the lining down into the bag.
   • Press Well: Press the entire bag, especially the top edge around the zipper, ensuring the lining is tucked neatly inside.
   • Final Topstitch (Optional): For a super professional finish, topstitch around the entire top edge of the bag, about 1/8" (0.3 cm) from the zipper. This helps the bag hold its shape and keeps the lining from peeking out.

V. Ideas for "Special" Touches:

• Keep Original Jean Details:
  • Use the back pocket as the front of your bag.
  • Incorporate the original hem of the jeans at the top or bottom of your bag.
  • Cut a piece of denim that includes the jean label for a unique branding.
  • Use the belt loops as a tab to attach a wrist strap or carabiner.
• Embellishments:
  • Add patches (iron-on or sewn-on).
  • Embroidery or fabric paint before assembly.
  • Sew on buttons, studs, or fabric scraps for a collage look.
  • Add a charm or tassel to the zipper pull.
• Straps/Handles:
  • Add a simple wrist strap made from denim scraps or a piece of the original waistband.
  • Attach a detachable crossbody strap using D-rings or swivel clips.
• Contrast Stitching: Use a contrasting color of heavy-duty thread for topstitching to mimic original jean stitching.

Enjoy your unique, upcycled zipper bag! It's a testament to creativity and sustainability.

Video Tutorial Here