Zippered boxed pouches fully lined without bias tape

Fully lined Boxy Pouch

Finished size: 11” x 5” x 5” (28cm x 12.5” x 12.5”)

Materials:
Outer-main fabric:
1 piece: 16” x 20” (40.5 cm x 50 cm)
Batting:
1 piece: 16” x 20” (40.5 cm x 50 cm)
Handle+tabs:
1 piece: 12.5” x 3.5” (32 cm x 9 cm)
Lining fabric:
2 pieces: 16”x10” (40.5 cm x 25.5”)
Zipper:
1 piece: 17” (43 cm)

seam allowance 3/8” (1 cm)

I like to use plastic zippers sold by the meter. They are affordable, available in many colors and they are easy to sew over, without the fear that the sewing needle might broke. While the easiest way to use them is to simply detach the sides and install the zipper pulls (sliders) only after sewing the zipper to both main fabric panel and lining, I filmed also the version with the zipper pulls on from the beginning, so I hope that this overlapping of two zipper methods will not be confusing.

Instructions:

Prepare the Fabric:
Cut the outer layer fabric, batting and lining fabric according to the specified dimensions. Cut the rectangle that will be used for the handle and tabs.
Ensure that all pieces are neatly cut to size. Quilt the main fabric to the batting as desired-this is to stabilize the fabric and give more structure to the bag. You can avoid this step by using some thicker fabric, like canvas or similar.
Clip the fabrics and zipper tape to mark the centers for easier matching.

Make the Handle and Tabs:

Take the 12.5” x 3.5” (32 cm x 9 cm) rectangle.
Fold the rectangle in half lengthwise and press along the fold to create a center crease.
Open up the fold and press both longer sides towards the center crease.
Fold the rectangle closed again along the original center crease.
Topstitch along both longer edges of the rectangle to secure the folds in place.
From this rectangle, cut the handle at 6.5” and the remaining 6” divide in half to obtain two 3” pieces that will be folded in half to become tabs.

Attach the Zipper:
-I have filmed 2 videos: one is showing the zipper with the pulls already on (in case that you are applying the regular, ready to sew zipper) while the other clip in the video is showing the easiest way to attach the plastic zipper and add the zipper pulls (sliders) by yourself. If you wish to add pulls on both ends of the zipper, take care to insert them in opposite directions—from the ends toward the center. Be mindful to avoid any weird bubbles forming, which can depend on how the zipper teeth are picked up in installation.

Place one outer layer piece face up.
Position the zipper face down along the top edge of the fabric.
Align one lining piece face down on top of the zipper.
Stitch along the edge to attach the zipper.
Repeat the process with the remaining outer layer and lining pieces on the other side of the zipper. Ensure that the sides are neatly overlapping and flat, then press them down. Proceed to top stitch along both sides of the zipper edge to secure them in place.

Create the Pouch Body:

Open the zipper halfway to facilitate turning the pouch right side out later.
I suggest to add the zipper tabs right now in the beginning, as it will also secure the sliders and prevent unzipping.
Trim off the excess of the zipper tape at this point.
Turn the pouch right sides inside and stitch the bottom edge of the lining layer, leaving a larger opening for turning. Finger or iron press this seam open, for easier stitching.
Fold the fabric pieces so that the outer layer pieces are right sides together, and the lining pieces are right sides together.
Finding your centers (clipped or marked at the beginning), align your bottom edges right sides inside so that they are overlapping the zipper that will be in the middle, make sure that the tabs are in, the zipper is in the center and that everything is even. Clip or pin together both sides.

Box the Corners:

Press your bag nicely, making sure that everything is aligned. Grab a marking tool and a ruler and measure 2 1/4” inch squares on all four corners. This will determine the height of the bag. You can adjust this size to 2” if you want it lower in height, but wider or to 2.5” if you want it taller in height, but narrower.
Before cutting, measure if the measurements between the central seam and the cut lines is the same on both sides and on all 4 corners and make sure to adjust accordingly, if needed. Use scissors to cut off the corners.
Stitch now both sandwich edges (with zipper in the middle) closed.
You can add the handle on one side of the bag by finding the center of your seams, securing the handle with the clip and sewing over. You can either sew it to just one side by securing it or you can clip it together with all two layers that will make the boxed corner and sew over. Making sure that the handle is going straight, you need to bring it to the other side and repeat the same process of aligning it to the center of your seam, securing and stitching it in place.

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