Customer Project: Backpack Pullouts

by Mountain Man 61

• OVERVIEW
• HOW DO I MAKE IT
• MATERIALS

• For years I've have just stuffed all my gear into my pack, like a bank robber with cash, only to not know where things are located and begin with the long dig to the center of the earth.  Stuff sacks are great for big things but when you have a lot of small things, you end up digging again, like the pack for things.  What I wanted was a zipper bag solution to be able to hold small things that I could easily see when I opened it, then I saw what I wanted to make on Kifaru's website ( https://store.kifaru.net/mobile/ultralight-pullouts-p22.aspx).

  
  

  Having never installed a zipper I leveraged the following site.

  
  

  https://youtu.be/en4pScOLZ9E Zipper Bag

  
  

  Note: This backpacking pouch is intended to be highly functional with strong durability at a low weight.  Ultralight materials can be substituted as you see fit.
• I started by making a 13.5" x 17" pattern out of butcher paper, this will account for a 1" seam allowance for the zipper.  The final product will be 13.5" x 8" (Large Pullout), able to hold gloves, hat, hand warmers, and scarf for your 'winter warm gear cache' pullout. (Photo 1)

  
  

  Next I laid the pattern over the material, traced and cut it out with scissors.  Optional: You can use a hot cutting knife. (Photo 2)

  
  

  Then I laid out the zipper to overhang each side of the material by about an inch.  The reason for the overhang is so I can sew just past the end of the material onto the zipper to create an end stitch close to the material edge. (Photo 3)

  
  

  Setting the zipper aside, I used office clips to create a 1/2" hem then sewed it in place on the wrong side of the material.  Did same for other side.  (Photo 4)

  
  

  Flipping the material over, I office clipped the right side of the material to right side of the zipper.  I did this for the other side as well. (Photo 5)

  
  

  Then I installed the zipper slider (Recommend watching https://youtu.be/en4pScOLZ9E Zipper Bag if unsure) (Photo 6)

  
  

  Flipped material inside out so wrong side of material was facing up, as well as underside of zipper.  Squared up material so zipper was centered. (Photo 7)

  
  

  With zipper centered I office clipped one side for sewing. (Photo 8)

  
  

  Sewed the side until I got to the zipper.  Then opened the zipper and inserted a folded over section of grosgrain.  Held zipper back in place and sewed over remaining side.  Did same process on other end of pouch. (Photo 9)

  
  

  Flip inside out and you have your final product.  (Photo 10)

  
  

  

• Required Materials:

  - 1 Yard - 1.6oz HyperD PU4000

  - 2x 5", Solid Grosgrain Ribbon, 3/4 Inch, Black 

  - YKK #8 Zipper Heavy Duty

  Related Products:

  • 1.6 oz HyperD™ PU4000
  • MIL-SPEC Nylon Grosgrain Ribbon
  • YKK Coil Zipper