Making a denim zipper tote bag from old jeans is a fantastic way to create a durable, stylish, and highly practical accessory. A zippered top is a great feature for a tote because it keeps your belongings secure, making it perfect for daily use, travel, or carrying valuables. Denim is an excellent choice for a hard-working bag, and using old jeans gives your project a unique, upcycled flair.
This detailed guide will walk you through sewing a classic denim tote bag with a structured, flat bottom and a secure top zipper closure. We'll aim for a finished size of approximately 14 inches wide, 12 inches tall, and 4 inches deep.
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How to Sew a Denim Zipper Tote Bag from Old Jeans
This project is suitable for intermediate sewers due to the zipper installation and the need for precision when working with thicker denim. However, the steps are detailed to help you achieve a professional-looking result.
I. Planning & Gathering Your Materials
Careful planning and the right materials will ensure your bag is both beautiful and functional.
Old Jeans:
Quantity: 1-2 pairs of adult-sized jeans. Look for sturdy, non-stretch or low-stretch denim. A consistent wash looks clean and classic, but you can also use a patchwork of different shades for a unique look.
Preparation: Wash and thoroughly dry your jeans before cutting. This prevents shrinkage later. Deconstruct them by unpicking seams to get the largest possible flat pieces of denim.
Lining Fabric:
Type: A durable woven cotton, like quilting cotton or broadcloth. A fun print or a bold, solid color can add a nice touch.
Quantity: Approximately 1 yard.
Preparation: Wash and iron.
Interfacing/Stabilizer (Crucial for Structure):
Type: You'll need two types for a professional, structured finish:
Medium-weight fusible interfacing (e.g., Pellon SF101 Shape-Flex) for the lining panels.
Heavy-weight fusible stabilizer (e.g., Pellon 809 Decor Bond) for the main denim body and bottom. This will give your tote its crisp, structured shape.
Quantity: Approximately 1 yard of each type.
Zipper:
Type: A sturdy nylon coil zipper is easiest to work with.
Length: At least 16 inches for the main bag opening.
Webbing for Handles:
Type: Cotton or polypropylene webbing, 1 inch wide.
Quantity: Two pieces, each 26 inches long.
Matching Thread:
All-Purpose Polyester Thread: For piecing and general seams.
Heavy-Duty/Topstitching Thread: In a contrasting or matching color for all visible topstitching and for securing the handles.
Basic Sewing Tools:
Sewing machine (a new denim needle or heavy-duty needle, size 16 or 18, is essential).
Zipper foot: A must-have for sewing close to the zipper teeth.
Walking foot (optional but highly recommended): Helps feed multiple thick layers of fabric evenly.
Sharp Fabric Scissors or Rotary Cutter and Mat.
Measuring Tape or Long Ruler.
Fabric Chalk, Frixion Pen, or Mark-B-Gone Pen.
Plenty of Fabric Clips or extra-long pins.
Iron and Ironing Board.
Seam Ripper (your best friend!).
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II. Prepare & Cut Your Fabric Panels
Precision in cutting and fusing interfacing is paramount. We will use a boxed corner method for a clean, professional finish.
1. Cut Main Bag Panels (Denim & Lining)
From your Denim (Exterior Fabric):
Main Exterior Panels: 2 pieces, 15 inches wide x 13 inches tall.
Optional Exterior Pocket: Carefully cut out a back pocket from your jeans, leaving about a 1/2-inch seam allowance around the stitched edges.
From your Lining Fabric:
Main Lining Panels: 2 pieces, 15 inches wide x 13 inches tall.
Zipper Top Panel: 2 pieces, 15 inches wide x 2 inches tall.
Interior Pocket Panel (Optional): 1 piece, 10 inches tall x 12 inches wide.
From your Interfacing/Stabilizer:
Heavy-weight stabilizer: Cut two pieces, 14 inches wide x 12 inches tall (for the main exterior panels).
Medium-weight interfacing: Cut pieces slightly smaller than all corresponding lining panels.
Fuse Interfacing/Stabilizer: Following the manufacturer's instructions, fuse the heavy-weight stabilizer to the wrong side of your denim exterior panels. Fuse the medium-weight interfacing to the wrong side of all your lining panels.
2. Prepare Handles
Cut two pieces of webbing, each 26 inches long.
III. Step-by-Step Sewing Instructions
Use a new denim needle and your heavy-duty/topstitching thread for all visible topstitching and for securing the handles. Backstitch at the beginning and end of every seam. Maintain a consistent 1/2-inch seam allowance unless otherwise stated.
Step 1: Add Exterior Pocket (Optional)
Take one of your Main Exterior Panels. Lay it right side up.
Position the harvested back pocket where you'd like it (e.g., centered on the lower half). Pin it securely.
Stitch the pocket onto the denim panel, very close to the existing stitched edges of the pocket. Reinforce the top corners with a small triangle or bar tack stitch for extra durability.
Step 2: Attach Handles
On the same Main Exterior Panel (with pocket if added), measure 4 inches in from each side edge along the top raw edge. Mark these points.
Place the raw ends of one webbing handle onto these marks, aligning the raw edge of the webbing with the raw top edge of the panel. The handle loop should face downwards onto the bag body.
Stitch the handle in place with a strong reinforcing stitch (e.g., a box stitch with an "X" inside it) within the 1/2-inch seam allowance.
Repeat for the second handle on the second Main Exterior Panel.
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Step 3: Install the Zipper
Lay one of your Main Exterior Panels (with handles) right side up.
Place the zipper right side down along the top 15-inch raw edge of the panel, aligning the zipper tape's raw edge with the fabric's raw edge. Center the zipper horizontally. Pin in place.
Take one Lining Zipper Top Panel (15" x 2"). Place it right side down on top of the zipper/exterior fabric sandwich, aligning all three raw edges. Pin all layers together.
Using your zipper foot, stitch along this pinned edge, as close to the zipper teeth as possible.
Open out the fabric, press the seam flat, and topstitch on the denim panel close to the seam line.
Repeat this process for the other side of the zipper, attaching it to the second Main Exterior Panel and the second Lining Zipper Top Panel. You should now have a complete "zipper unit." Open the zipper halfway! This is crucial for turning the bag right side out later.
Step 4: Assemble the Exterior Bag
Take the two Main Exterior Panels (with the zipper attached) and align them right sides together. Make sure the zipper is aligned.
Pin the side seams and the bottom seam. Sew with a 1/2-inch seam allowance.
Create boxed corners: At each bottom corner, measure a 2-inch square. Cut out these squares. Now, pinch the bottom seam and side seam together, right sides facing, and align them so the raw edges of the cutout square meet. Pin and sew with a 1/2-inch seam allowance. This creates the flat, structured bottom of your bag.
5. Assemble the Lining Bag
Follow the same steps as in Step 4 to assemble the two Main Lining Panels.
Crucially, leave a 5-6 inch opening in the middle of the bottom seam. This is for turning the bag right side out.
6. Combine and Finish the Bag
Turn the denim exterior bag right side out.
Turn the lining bag inside out.
Carefully insert the denim bag into the lining bag, so that their right sides are facing each other. The handles should be tucked down between the layers.
Align the side seams of the denim and lining. Pin the top raw edges of the bag together.
Stitch all the way around the top with a 1/2-inch seam allowance.
Turn and close: Pull the entire bag right side out through the opening in the lining's bottom. Push out the corners and seams, then press the seam allowances of the opening in the lining under and stitch it closed.
Push the lining into the bag and give the entire bag a final press, paying special attention to the zipper area to make it lie flat.
Congratulations! You've successfully sewn a durable and unique denim zipper tote bag from old jeans! It's ready to carry your essentials securely.
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