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Welcome to Day 3 of the Caravan Tote Sew Along.  Today we’ll construct the exterior of the bag.  Check out Day 1 to get started and learn about fabric and interfacing selection, and Day 2 to begin cutting and making handles. You can purchase the PDF from the Noodlehead shop, and use code HOSAL at checkout to save 20%. I also noticed that you can get a kit including the paper pattern and fabric from Craftsy, on sale right now, save 35%.

To prepare the zipper, we’ll add zipper tabs on each end. The zipper tabs make it easier to sew in at the seams. If you are using a premade zipper, you may need to trim the ends of the zipper so they don’t extend more than 1/2″ past the metal stop and start of teeth. Create a zipper sandwich with lining tab right side facing up, then zipper facing up and finally exterior tab right side down. Sew in place with your zipper foot (being careful to avoid the metal zipper end).

Then move tabs out, away from zipper so they are wrong sides together. Press and topstitch. Repeat with other zipper end and trim tabs so they match the zipper width, if you need to.

To create the large front zippered pocket, start by taking the Contrast Top Exterior and align the raw edge with the zipper (teeth down). Note: If your Contrast Top is directional, you will be matching the bottom raw edge with your zipper – in my picture, the purple diagonal lines are the top of my bag. I like to use Wonder Clips here and because I’m using a wider zipper, I don’t need to use a zipper foot. You may choose to use a fusible tape to help secure the zipper while you sew.

Baste in place and then place Contrast Top Lining right side down, aligning it with the Contrast Top Exterior; stitch in place.  Fold back away from zipper, joining both Contrast Tops wrong sides together and press. Trim excess width from zipper tabs.

Now repeat those steps with other side of zipper, Main Exterior, and Lining Exterior. You will have the right side of the Contrast Top Exterior touching the right side of the Main Exterior while you baste the zipper in place.

Once the Exterior and Lining pieces for Main and Contrast Top are all sewn to the zipper, press in place and topstitch. Trim completed Front to a height of 17 1/2″. Mark a horizontal line 3″ up from bottom edge of Exterior front and sew through all layers.

Depending on the fabric and/or interfacing you chose, you may wish to add a layer of interfacing or fleece to your pocket and flap. If you’re using a metal snap I recommend reinforcing your fabric. For mine, I will be using the Half Moon Magnetic Edge Clasp so I need to add the female magnetic snap half before I finish sewing my pocket. If you’re using a traditional magnetic snap (or 2) you’ll need to add those before you sew the flap together.
I cut a scrap piece of fusible fleece a tad smaller than the flap and fused to the wrong side of my Exterior Pocket Flap. Place Pocket Flap pieces right sides together and sew sides and curved edges only, leaving straight edge unsewn. Clip curved edges within seam allowance, being careful not to cut into stitching. Turn right side out, press, and topstitch. Feel free to add another line or 2 of topstitching here.

As with the pocket flap, you may wish to add extra interfacing or scraps of fleece for reinforcement for the closure of your pocket. Place pocket pieces right sides together. Stitch together starting at the top straight edge, going around back to the top straight edge, but leave a turning hole about 4″ at the top straight edge of the pocket. Clip curved edges and corners within seam allowance and turn right side out. Use a turning tool to create nice corners and smooth curves. Tuck in fabric at turning hole, press in place. If you need to add a magnetic snap, you can do that now. Topstitch along straight edge, with additional rows as desired.

Measure 2 1/4″ down from zipper and place pocket top along that line. Center pocket (mine was 4 1/4″ from each side), pin in place and sew through all layers, adding a diagonal line for reinforcement at each top corner.

To attach the flap, first place pocket Exterior side down, with raw edge closest to pocket, 1″ above top of pocket, then sew along raw edge with a 1/8″ seam allowance. Then fold down and press in place, then stitch along top folded edge with a 1/4″ seam allowance, hiding the raw edge.

Place remaining Contrast Top down against remaining Exterior Main, right sides together (the contrast top should be upside down if it’s directional). Stitch together, press seam open and topstitch along Contrast Top.

That’s it for now! The next day we will create the needle pocket for the zippered pocket lining, and create lining of bag, including slip pocket.

I’d love to see your progress! Tag me and use #CaravanToteSAL on Instagram.

Feel free to leave a comment if you have any questions, or suggestions. Do you have any zipper tips? Favorite closures for flaps? Let us know!

To enter to win the Noodlehead patterns, submit a photo of your completed bag by July 3, either by uploading it on my contact page, or using #CaravanToteSAL on Instagram by July 3, 2016.