Today I’d like to share with you my very first tutorial. It’s for an insulated lunch bag, with a zippered top. If you’re a beginner, don’t let the zipper scare you. It’s actually quite simple, but the finished product looks great! I started making these because I found all the store bought lunch bags were too small to fit all my reusable containers, so this bag is bigger than the average lunch bag, but I think it’s the perfect size (about 12″ tall, by 10″ wide and 5″ across/deep).

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?! 

 Materials needed: 

• 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

Note: Jersey/ballpoint needles are recommended for sewing PUL. I also use clips instead of pins when sewing with PUL; these are also available at Funky Monkey. Also, I pieced some red Kona cotton onto the superkids, feel free to use one piece for the panel, or do any type of patchwork you like, as long as the finished panel sizes are 13″x16″

Attaching handles:

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. 

Zipper:

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 with zipper teeth down and cotton right side up, layer PUL (shiny side touching zipper) and insulbright onto back side of zipper, clip/pin in place, flip over (so you see your basting stitch) and sew together right over basting stitch. 

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. 

Assembling bag

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. 

Starting along one side of the lining (PUL/insulbright), using a 1/2″ seam allowance, sew down toward the bottom of the lining, around the perimeter, leaving a 4″ hole for turning, making sure to backstitch at start and end. Trim seam allowances and zipper if applicable, but leave seam allowance over turning hole intact. 

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. 

Boxed corners

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

Finishing bag 

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!

Tuck seam allowance in at turning hole and finger press the edge, clip in place and sew with a very small seam allowance, or hand stitch using blind stitch if you prefer. 
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. 

Push the lining into the outer bag, and voila: your bag is done! 

If you have any questions, feel free to comment below or send me an email. I’d love to hear if you end up making your own!