How to make a zippered pouch with a gusset

Making a zippered pouch with a gusset is a great sewing project that results in a sturdy and versatile pouch with extra space. Here are step-by-step instructions on how to make one:

Materials You’ll Need:

  • Fabric for the exterior (choose a sturdy fabric like cotton canvas or upholstery fabric)
  • Fabric for the lining
  • Zipper (at least the width of your pouch)
  • Fusible interfacing (optional, for added stiffness)
  • Sewing machine
  • Scissors
  • Pins
  • Iron and ironing board
  • Zipper foot for your sewing machine (helpful but not required)


1. Prepare Your Fabric:

  • Wash, dry, and iron your fabric to remove any wrinkles or sizing.
  • Cut two rectangles from your exterior fabric and two from your lining fabric. The size of these rectangles will determine the dimensions of your pouch. For a gusseted pouch, you’ll want them to be a bit taller than the desired height of your pouch and double the desired width plus a seam allowance.

2. Add Interfacing (Optional):

  • If you want your pouch to be stiffer, apply fusible interfacing to the wrong side of the exterior fabric rectangles following the manufacturer’s instructions.

3. Prepare the Zipper:

  • Place the zipper face down on one of the exterior fabric rectangles, aligning the top edges. The zipper pull should be on the right side.
  • Lay one of the lining fabric rectangles on top, aligning the top edges with the exterior fabric and zipper. Pin these layers together.

4. Sew the Zipper:

  • Use your sewing machine’s zipper foot (if available) to stitch along the pinned edge, securing the zipper in place. Be sure to backstitch at both ends.

5. Repeat for the Other Side:

  • Open up the fabrics and press them flat. You’ll now have one side of the zipper attached.
  • Repeat the process for the other side of the zipper, attaching it to the remaining exterior and lining fabric rectangles. When you’re done, you’ll have two sets of fabric attached to the zipper, one on each side.

6. Create the Gusset:

  • Open the zipper about halfway to ensure you can turn the pouch inside out later.
  • Fold the exterior fabric right sides together, aligning the side seams. Pin along the sides and bottom. Do the same for the lining fabric.

7. Sew the Sides and Bottom:

  • Using a straight stitch, sew along the pinned sides and bottom of both the exterior and lining fabrics, leaving a 14-inch seam allowance. Be sure to backstitch at the beginning and end of your stitches. Leave the corners unsewn.

8. Box the Corners:

  • To create a gusset, pinch the corners of the exterior fabric and lining fabric together so that the side seam aligns with the bottom seam. This forms a triangular shape at each corner.
  • Measure about 1 inch from the tip of the triangle and draw a line perpendicular to the side seam. Pin the layers together along this line.
  • Stitch along the line, creating a box corner. Repeat this step for all four corners.

9. Trim Excess Fabric:

  • Trim the excess fabric from the boxed corners, leaving about 14 inch from the seam. This reduces bulk.

10. Turn the Pouch Right Side Out: – Carefully turn the pouch right side out through the open zipper.

11. Final Touches: – Press the pouch flat to make sure the seams are crisp. – Zip the pouch closed.

Your zippered pouch with a gusset is now complete! You can use it for various purposes, such as a makeup bag, toiletry kit, or a stylish clutch. Customize it with different fabrics and embellishments to make it your own.

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