How to Sew an Insulated Lunch Box

Step-by-Step Guide

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   Step 1: Obtain the items listed below in the "Things You Will Need" section.

   You'll need an old newspaper sheet or craft paper for this. ,(see pic for help) Begin with a
   10.5 x
   20.5 inch rectangle. , Note, this flap shape can be modified to nearly any shape.
   
   The author has modified it to a rounded shape to simulate the face/head of a pig. (See tips) ,, One from outer shell fabric, one from inner shell fabric, one from insulation and one from interfacing. ,,, First the outer layer, then the inner layer, then your insulation., Inner and outer layer should be facing, insulation can be on the back of either layer.,,,,,, You can add "quilting" stitches to the bag at this point to help hold the layers together if you wish.,,, You "can" turn the bag back "inside out" for this process to give you better access to the seam you are sewing., Sew it in place., Pin ends of webbing in place.
   
   Machine sew them to the bag.
   
   You can do this as a single loop from one narrow side of the bag to the other, or you can do this as a double D handle, sewing one D to the back of the bag and one D to the front of the bag under the flap.,
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   Step 2: Launder all fabrics to remove sizing

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   Step 3: starches

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   Step 4: Iron the fabrics smooth if necessary.

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   Step 5: Measure and mark your basic pattern on paper.

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   Step 6: *Note that the measurements allow a quarter inch (1/2 cm) seam allowance on all pieces.

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   Step 7: Add a 6 x 6 flap to the top edge as shown.

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   Step 8: Add a 4.5 x 6.5 flap to the bottom edge as shown.

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   Step 9: Cut four of this main pattern.

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    Step 10: Mark the long edges of the rectangle with pins to mark your bag's "corner edges".

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    Step 11: Iron the interfacing to your outside fabric to stiffen it.

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    Step 12: Sew the short sides of your rectangles together.

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    Step 13: Assemble and pin all three layers together with their top flap edges together.

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    Step 14: Sew along the opening edge.

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    Step 15: Clip insulation back to the seam line.

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    Step 16: Clip all corners to ease turning.

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    Step 17: Pin and sew the OUTER fabric bottom rectangle to itself to form the bottom.

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    Step 18: Turn the bag right side out.

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    Step 19: Pin the top edge and then top stitch it to hold it in place.

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    Step 20: Add your cardboard or plastic stiffening to the inside bottom of the bag.

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    Step 21: Hand tack the stiffening to the bottom.

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    Step 22: Hand sew the liner bottom to the liner sides

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    Step 23: taking care to turn raw edges under.

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    Step 24: Fold over top closure flap and mark the placement of your Velcro closure.

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    Step 25: Mark handle positions.

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    Step 26: Customize - Will add ideas here later.

Detailed Guide

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