All the materials in this bag can be found at Funky Monkey Fabrics, including this adorable superkids cotton. My youngest son picked it out and he's thrilled to have his new "super" lunch bag. Melissa, of Funky Monkey Fabrics strives to carry fun fabric at competitive prices, and I think she hits the mark. She's even offering kits that include everything you need to make this lunch bag, how great is that?!
- 2 each of 13" x 16" cuts of insulbright, PUL, and cotton (for ordering purposes, 1/2 yard of 42-44" cotton and Insulbright, and less than 1/2 yard of 60" PUL should be more than enough)
- 14" or longer zipper
- 2x 16" pieces of 1" wide webbing (be sure to heat seal the edges so they don't fray)
- Coordinating thread, sewing machine, zipper foot, sewing shears or rotary cutter, and other basic sewing supplies
Pin one end of webbing 3 1/2" from side of one cotton panel onto the right side of the top 13" edge, then pin other end of webbing 3 1/2" from other side of panel, so the inner edges of the webbing are 4" away from each other. Machine baste in place with a 1/4" seam allowance.
Repeat with other cotton panel and piece of webbing.
Place zipper with teeth up, and line up top 13" edge of cotton, right side down onto zipper, sandwiching the handle between the outer cotton panel and the zipper, clip/pin and machine baste in place using zipper foot at a small seam allowance.
Now fold back, so wrong side of cotton is touching insulbright, and materials are out of the way, and repeat above steps to attach remaining panels to other half of zipper, making sure to match up sides of panels.
This part is almost like sewing 2 bags. Line up cotton right sides together, and align insulbright and PUL, with PUL right sides together, the zipper will act as a divider between both bags.
Pin in place all around and make sure zipper teeth are facing in to the lining side (PUL). At this point, you'll want to make sure your zipper pull is inside the seam allowance and that the zipper is opened at least half way.
Tip: try using a 5/8" seam allowance while sewing the lining, but taper to 1/2" toward zipper and use 1/2" throughout cotton, then taper back to 5/8" for remaining lining stitching, this will make the lining fit better inside the exterior of the bag.
To make boxed corners, while wrong sides still facing out, pinch a corner seam, matching the side seam and bottom seam, mark a line 2" in from corner point, and stitch along that line. Repeat for remaining 3 corners. Trim corners
Turn bag right side out through turning hole. It may help to reach in and undo the zipper all the way. At this point, you might be questioning whether you left the turning hole big enough...hang in there! Just go slow, and you'll get there!
Tip: you'll need a Teflon foot or walking foot for this step, as you'll be sewing the shiny side of the PUL, or you could use freezer paper, wax paper, or even tissue paper over the seam with your regular presser foot, and tear away after you've sewn the hole shut. I've heard putting scotch tape on the bottom of the presser foot works well too.