Looking for a chic and sturdy way to organize your essentials? This DIY denim barrel bag is the perfect solution! Its cylindrical shape makes it spacious, and the zippered top keeps everything secure. Ideal for cosmetics, art supplies, small tools, or even as a unique gift, this project is also a fantastic way to upcycle old denim. Plus, the contrasting handles add a pop of personality!
Let's get rolling and sew this stylish and practical denim pouch!
Skill Level: Intermediate (familiarity with zippers and sewing curves is helpful)
Materials You'll Need:
Denim Fabric: From 1 pair of adult-sized jeans or sturdy denim scraps. You'll need enough to cut the main body and side panels.
Lining Fabric: 1/2 yard (0.45 meters) of cotton quilting fabric or other durable fabric (like the olive green in the image).
Heavy-Duty Zipper: 14-16 inches (35-40 cm) long (matching the main body length).
Webbing/Ribbon for Handles: 1 yard (0.9 meters) of 1-inch (2.5 cm) wide cotton webbing, sturdy ribbon, or twill tape (like the olive green/striped in the image).
Medium-Weight Fusible Interfacing: 1/2 yard (0.45 meters) of 20-inch wide interfacing (Pellon SF101 or similar).
Coordinating all-purpose thread.
Sewing machine with a denim needle (essential!) and zipper foot.
Fabric scissors.
Pins or fabric clips.
Measuring tape or ruler.
Fabric marker or chalk.
Iron and ironing board.
Finished Bag Dimensions (Approximate): Length: 13-14 inches (33-35.5 cm) Diameter: 5-6 inches (12.5-15 cm)
Preparation: Deconstructing Your Jeans (if applicable)
Wash and Dry: Wash and dry your jeans or denim scraps.
Open Leg Seams: Cut along the inner seam of jean legs to open them into flat pieces. Press them flat with an iron.
Cutting Your Fabric Pieces:
All seam allowances are 3/8 inch (1 cm) unless otherwise stated.
From Denim Fabric:
Main Body (1 piece): 14 inches (35.5 cm) wide x 18 inches (45.5 cm) long.
Note: This piece will form the circumference and length of your barrel. The 14" side will be the length of the bag, and the 18" side will wrap around.
Side Panels (2 pieces): Cut two circles or squares (which you'll round later) measuring 6 inches x 6 inches (15 cm x 15 cm).
From Lining Fabric:
Main Body Lining (1 piece): 14 inches (35.5 cm) wide x 18 inches (45.5 cm) long.
Side Panels Lining (2 pieces): Cut two circles or squares measuring 6 inches x 6 inches (15 cm x 15 cm).
From Medium-Weight Fusible Interfacing:
Main Body Interfacing (1 piece): Cut to match Main Body.
Side Panels Interfacing (2 pieces): Cut to match Side Panels.
Sewing Instructions:
Part 1: Prepare Interfacing & Handles
Fuse Interfacing: Following the manufacturer's instructions, fuse all medium-weight interfacing pieces to the wrong side of their corresponding denim fabric pieces (Main Body and Side Panels).
Prepare Handles:
Cut your webbing/ribbon into two equal pieces, each 18 inches (45.5 cm) long.
(Optional: If using a thin ribbon, you might want to fold it in half lengthwise and sew along the edge for a sturdier handle. If using thick webbing, no extra steps are needed.)
Part 2: Attach Zipper to Main Body
Main Body Piece: Take your denim Main Body piece. Lay it flat, wrong side up.
Position Handles: Measure 4 inches (10 cm) in from each of the 14-inch raw edges (these are the edges that will attach to the zipper). Pin one end of a handle on each side, centered on the width, about 1/2 inch (1.25 cm) from the raw edge. The handles should be positioned so they loop inwards towards the center of the fabric. Baste in place.
Attach Zipper:
Place your zipper right side down along one of the 14-inch raw edges of the denim Main Body piece. Align the zipper tape edge with the fabric raw edge. Pin securely.
Using your zipper foot, sew the zipper to the denim.
Repeat with the Main Body Lining piece: Place the remaining raw edge of the zipper (with denim attached) right side down along one 14-inch raw edge of the Lining Main Body piece. Pin and sew.
When you're done, the zipper should connect the denim and lining pieces. Press the fabric away from the zipper teeth.
Topstitch along both sides of the zipper, close to the teeth, to create a neat finish and prevent fabric from getting caught.
Part 3: Form the Barrel Shape
Sew Side Seams:
Open your zipper halfway.
Bring the two unsewn long edges of the denim Main Body piece together, right sides facing. Pin to form a tube. Sew this seam. Press seam open.
Repeat for the lining: Bring the two unsewn long edges of the lining Main Body piece together, right sides facing. Pin and sew this seam. Press seam open.
You now have two tubes: a denim outer tube and a lining inner tube.
Part 4: Create and Attach Side Panels
Shape Side Panels:
Take your two denim Side Panel squares (with interfacing fused). Fold each into quarters to find the center. Using a circular object (like a bowl or compass) with a 5.5-inch (14 cm) diameter, draw a circle on each square. Cut along the drawn line to create perfect circles.
Repeat for the two lining Side Panel squares.
Attach Denim Side Panels:
Take one denim circular Side Panel. Pin it to one open end of your denim Main Body tube, right sides together. This is a curve, so pin frequently and ease the fabric as you go.
Sew slowly around the entire circle with a 3/8 inch (1 cm) seam allowance. Take your time to get a smooth curve.
Repeat for the second denim Side Panel on the other end of the denim tube.
Turn the denim outer bag right side out.
Attach Lining Side Panels:
Take one lining circular Side Panel. Pin it to one open end of your lining Main Body tube, right sides together. Sew.
Repeat for the second lining Side Panel on the other end of the lining tube.
You now have a complete lining bag (wrong side out).
Part 5: Final Assembly
Insert Lining:
Make sure your zipper on the main bag is still open.
Carefully insert the denim outer bag (right side out) into the lining bag (which is still wrong side out).
Align the seams of the side panels and main body as best you can.
Working through the zipper opening, gently push the lining into place so it sits neatly inside the denim bag.
Close Opening (Optional - if you prefer a fully finished lining):
If you want to fully enclose the lining, you can use fabric glue or small hand stitches to secure the lining to the seam allowance of the zipper tape on the inside.
Or, you can leave it as is, as long as the side panels are securely sewn.
Weave in Ends: Trim any excess threads and securely weave in all loose ends.
You're Done!
Congratulations! You've just sewn a fantastic and functional denim barrel bag. It's perfectly sized for so many uses and showcases the timeless appeal of upcycled denim. The contrasting handles add a pop of color and make it easy to carry.
Fill it with your favorite goodies and enjoy your stylish new creation! Share your barrel bag projects with me on social media using #DenimBarrelBag – I'd love to see your unique fabric combinations! Happy sewing!
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