Overnight Duffel Bag Tutorial

I needed an overnight bag to take on trips. This bag was the perfect size and was sturdy, meaning I wanted it to stand up on its own. And I want to teach you to make one for yourself or for a gift, or heck, you can even sell these babies! So let’s get started.

Supplies Needed for the overnight duffel bag tutorial:

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Brother Sewing Machine – https://amzn.to/3vGr51I

Singer Sewing Machine – https://amzn.to/3IJdEBZ

Brother Embroidery & Sewing Machine – https://amzn.to/3IYX9Ss

Rotary Mat – https://amzn.to/3wiarWw

Rotary Cutter – https://amzn.to/36didX1

Quilting Ruler – https://amzn.to/3wfVlRo

Iron – https://amzn.to/3JpI24p

Sewing gauge – https://amzn.to/3wkkYjb

Scissors – https://amzn.to/3KbORaY

Tape measure – https://amzn.to/3wp82bE

Sewing clips – https://amzn.to/3hbD0Qc

Zipper 24” – https://amzn.to/3Cuwj2J

Bosal In-R-Form Double Sided Fusible – https://amzn.to/42G46Ra

Cotton Webbing – https://amzn.to/3p8TQDl

Fabric needed and Cutting Instructions:

Outer Fabric – 1 yard:

(2) 9″x19″ for top panels

(2) 7 1/2″x 8 1/2″ for side panels

(2) 4 1/4″x 24″ for zipper panels

Lining Fabric – 1 yard:

(1) 19″x32″ for main body

(2) 7 1/2″x 8 1/2″ for side panels

(2) 4 1/4″x 24″ for zipper panels

(2) 1 1/2″x 8 1/2″ binding for zipper panels inside

(1) 1 1/2″x 85″ binding for inside bag cut on the bias

Pocket Fabric:

(2) 8″x11″ for front and back pocket

(2) 8 1/2″x 12″ for side pockets

Accent FabricS:

(1) 15″x19″ for outside bottom

(2) 1 1/2″x 8 1/2″ binding for side pockets

(2) 1 1/2″x 8″ binding for front and back pocket

24″ x 58″ Bosal fusible foam double sided – Cut:

(1) 19″x32″ for main body

(2) 7 1/2″x 5″ for front/back pockets

(2) 7″x 8″ for side pockets

(2) 5 1/2″x 8″ for side panels

(2) 3 1/2″ x 23 1/2″ for zipper panels

Decorative ribbons 1 1/4 yard- Cut:

(2) 19″ strips x 1″

Cotton Webbing 4 yards Cut:

(2) 1″ x 38″ strips for straps

Zipper 24″ or longer

This bag was inspired by Erica Arndt, She is amazing! Thank you Erica!

First – We will start with the front pockets. Put the foam on the wrong side of fabric. It will be 1/4″ shorter on all sides to account for the seams. Fold over the other half and iron on both sides so the bosal foam will adhere. Now it is fused inside the pocket.

Second, we are going to quilt it. You can quilt it however you like. For the front/back pocket pieces, I quilted diagonal lines about an inch apart.

Third, we will topstitch the raw edges 1/8″ from the raw edge. This will keep our layers together to prevent them getting caught up later.

If you would rather watch a video on all this process, I made a YouTube Video for you to follow along. I really hope you will attempt to make this beautiful bag.. I used some fabric from my stash.

Watch the video here on YouTube. Don’t forget to subscribe.

Repeat the process above (all 3 steps) for the side pockets.

Repeat the process above (all 3 steps) for the side panels and the zipper panels. Except, you will use the outside fabric and the lining fabric, and of course the bosal foam. I did quilt my zipper panels longways instead of diagonally.

Before we start putting it together, let’s get that binding on the folded edge of all the pockets. Put the binding strip on the top folded edge of the pockets (all 4). Put right sides together and sew 1/4″ seam allowance.

Flip to the back, and fold 1/4″ under. Clip or pin to hold it in place. Sew 1/8″ seam allowance from folded edge. This just makes your bag alot cuter, aka decorative, and helps to use up a fat quarter or two that you have in your stash.

Zipper Panel Assembly for overnight duffel bag tutorial

Place zipper panels face up. Be mindful of directional fabric. Place the zipper face down in the center of the two panels. The zipper tab is toward your left.

Clip or pin in place. Line up so that the zipper hangs over the edge of the quilted piece 1/8″ so the zipper covers the raw edge.

Open zipper half-way. Stitch the zipper down. Press toward the lining so the zipper sits flat.

Topstitch that side down close to edge.

Place other zipper panel on top of zipper with right sides together. Stitch down and topstitch.

Run a seam along each end of zipper to hold the panels together.

Next, place a side panel at each end of zipper panel with right sides together. Pin in place. Subsequently, place the zipper panel binding piece right side down on top of side panel adding under the pins.

Sew a 1/4″ seam on each side. This attaches the zipper panel, the side panel, and the binding. BE CAREFUL not to sew over the zipper tab.

Press the binding toward the zipper. Fold under 1/4″. Stitch the binding down on folded edge with a 1/8″ seam allowance.

Add side pockets at the bottom of the side panels, lining up the raw edges. Baste the three raw edges together on each end, leaving the top of the pocket open.

Body Assembly for overnight duffel bag tutorial

Take bottom piece (the 15″ x 19″ accent fabric) Place right side up. Place the top panels, right side down on each end of the bottom piece. (Right sides together). Clip together in middle. BUT FIRST – Place the straps (cotton webbing) in between layers. put end of strap 5 1/4″ away from the sides. Put one strap on each end. Make sure it’s not twisted.

Clip together.

Sew a 1/4″ seam allowance. Sew on both ends of bottom piece. Press handles and seams toward center.

Sandwich foam between lining piece and body assembly and fuse with iron. Move handles out of the way to fuse. Next up – Quilt this assembly making sure to move the straps out of the way. You can quilt one part horizontal and the other part diagonal. It adds interest. Topstitch 1/8″ around entire raw edges.

Center the pockets underneath the straps on each side and pin down. Using a denim needle, stitch straps down with a 1/8″ seam allowance, stopping 1 1/2″ from top, and making an X at top of strap.. Repeat on other strap.

To close up the bottom of the pocket, add a decorative ribbon across the seam. Stitch on both sides of the ribbon. There will be about 1/2″ overlapping on each side of the seam.

Round the corners

Round the corners. Cut them all the same.

Find the centers of all four sides on the body assembly and mark. Additionally, find the centers of all four sides of the zipper assembly.

Match the centers, match the bottom of the side panel to the bottom panel, subsequently also match the center of the zipper panel to the front and back. Clip or pin together. Tuck the straps in the pockets to keep them out of the way. Pin all the way around. Make sure the zipper is mostly unzipped so you can turn your bag.

Putting it all together

Additionally, clip the curves where you rounded the corners to help it fit. Sew together using a 3/8″ or 1/2″ seam allowance. Finally, check all seam lines and make sure they are all caught good.

Binding for the overnight duffel bag tutorial

Add the bias binding to the seam you just finished with right sides together Start the binding folding a triangle down and end 2″ past beginning. That way you don’t have to try and match it up at the end.

Flip binding over the seam. Turn under 1/4″ and pin in place.

Sew down 1/8″ to attach binding and finish out the seam.

Turn right side out and poke out the corners. Voila – your new overnight duffel bag!!

PS – I had eye surgery a week before to repair a hole in my macula, therefore I have a gas bubble in my eye. I was basically sewing with only one eye. My friend called me The Sewing Pirate. LOL. I’m usually a perfectionist, however, only seeing from one eye, it’s not my usual best. All that to say – YOU CAN DO IT!! Now let’s go on a weekend getaway. What’s your favorite place to get away?

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If you liked this tutorial, you will probably be interested in my tote bag. Check it out, friend!

Another point of interest could be my zippered cosmetic bags. Enjoy!