Have a favorite old knit top or t-shirt that's seen better days, but the fabric is still super soft and comfy? Don't let it become a rag! You can give it a brand new purpose by transforming it into a pair of custom-fit, incredibly comfortable briefs or underwear. This upcycling project is not only sustainable but also a great way to ensure you have basics that truly fit and feel good.
This tutorial will guide you through turning a knit top (like the striped one pictured!) into a pair of everyday underwear, perfect for lounging or wearing under clothes.
Why You'll Love This Project:
Ultimate Comfort: Uses soft, familiar knit fabric for supreme comfort.
Eco-Friendly: Gives new life to old garments, reducing textile waste.
Cost-Effective: Make new undies without buying new fabric.
Custom Fit: Tailor them perfectly to your body.
Unique Designs: Use fun patterns from old tops for one-of-a-kind underwear.
Beginner-Friendly (with care): A great way to practice sewing with knits and elastic.
What You'll Need:
1 Knit Top/T-Shirt: Choose one with a good amount of stretch (like jersey knit). The larger the top, the more fabric you'll have. The striped top in the image is ideal!
A Pair of Well-Fitting Underwear: This will be your pattern guide. Choose a pair that you find very comfortable.
Sewing Machine: With a ballpoint or stretch needle (essential for knit fabrics!).
Matching Polyester Thread.
Fabric Scissors.
Measuring Tape or Ruler.
Fabric Chalk or Washable Marker.
Pins or Wonder Clips: Clips are excellent for knit fabrics as they don't snag.
Elastic:
For Waistband: 3/4 inch to 1 inch (2-2.5 cm) wide elastic.
For Leg Openings: 1/4 inch to 3/8 inch (0.6-1 cm) wide elastic, or narrow lingerie elastic.
You'll need enough of each to go around your body parts + overlap.
Optional: Small scrap of cotton jersey or other soft fabric for the crotch lining (if your top's fabric isn't suitable, or you want extra layering).
Step-by-Step Pattern & Sewing Guide:
Step 1: Prepare Your Fabric & Create Your Pattern
Deconstruct Top: Carefully cut off the bottom hem of your knit top. If needed, unpick the side seams to get the largest, flattest possible pieces of knit fabric. Press flat.
Prepare Guide Underwear: Take your well-fitting pair of underwear and fold them neatly in half lengthwise.
Trace Pattern Pieces: You will typically need three pieces: a front, a back, and a crotch gusset (lining).
Main Fabric Fold: Fold your prepared knit fabric in half lengthwise (stretch running across the fold if possible).
Trace Front Piece: Place the folded front of your guide underwear onto the folded fabric, aligning the center front with the fabric fold. Trace around the entire piece, adding 1/2 inch (1.25 cm) seam allowance everywhere except the center front fold. Mark the bottom of the crotch area.
Trace Back Piece: Move your guide underwear. Place the folded back of your guide underwear onto the same or another folded fabric section, aligning the center back with the fabric fold. Trace, adding 1/2 inch (1.25 cm) seam allowance everywhere except the center back fold. Mark the top and bottom of the crotch area.
Trace Gusset: For the crotch gusset, measure the width and length of the crotch area on your traced front and back pieces. Cut a small rectangular or slightly hourglass-shaped piece that matches this, adding 1/2 inch (1.25 cm) seam allowance around all sides. Cut one from your knit top fabric and one from your optional cotton jersey lining.
Cut: Carefully cut out all your pieces.
Step 2: Sew the Briefs
Attach Front to Gusset: Take your front underwear piece and one gusset piece. Place the front piece right side up. Place one gusset piece (the main fabric one) right side down, aligning the top crotch edge of the gusset with the bottom crotch edge of the front piece. Stitch across this seam with a 1/2 inch (1.25 cm) seam allowance. Use a zigzag stitch or stretch stitch.
Attach Back to Gusset: Take your back underwear piece. Now, take the remaining gusset piece (the lining).
Place the back piece right side up.
Place the main fabric gusset piece (already attached to the front) right side down, aligning its other short end with the bottom crotch edge of the back piece.
Place the lining gusset piece right side down on top of the back piece, aligning its short end with the same bottom crotch edge.
Pin all three layers together (back piece, main gusset, lining gusset). Stitch across this seam with a 1/2 inch (1.25 cm) seam allowance, ensuring all layers are caught.
Close Gusset: Fold the lining gusset piece over so it meets the other raw edge of the main gusset piece. Your underwear should now be forming a circle with a hidden gusset seam. Pin the remaining raw edges of the gusset pieces together along the crotch curve. Stitch these raw edges together. This creates a neat, enclosed crotch seam.
Sew Side Seams: Place the front and back underwear pieces right sides together, aligning the side seams. Pin and stitch with a 1/2 inch (1.25 cm) seam allowance. Press seams open. Finish raw edges.
Step 3: Add Elastic to Leg Openings
Measure Elastic: For each leg opening, measure the elastic to fit snugly around your leg at the desired opening, subtracting about 1 inch (2.5 cm) for a bit of stretch and hold. (Or simply wrap it around your leg and pull slightly taut). Add 1/2 inch (1.25 cm) for overlap.
Join Elastic: Overlap the ends of each elastic piece by 1/2 inch (1.25 cm) and stitch securely with a zigzag stitch to form a loop.
Attach Elastic: Divide your elastic loop and leg opening into quarters and mark. Align these marks. Place the elastic against the wrong side of the leg opening's raw edge, slightly stretching the elastic to fit the fabric as you sew. Use a zigzag stitch to attach the elastic.
Finish Leg Opening: Fold the elastic and the fabric edge towards the wrong side of the garment, so the elastic is now enclosed. Stitch again with a zigzag stitch, about 1/4 inch (0.6 cm) from the finished edge, stretching as you sew. This creates a neat, stretchy hem. Repeat for the other leg.
Step 4: Add Elastic to Waistband
Measure Elastic: Measure your waistband elastic to fit snugly around your natural waist, subtracting about 1-2 inches (2.5-5 cm) for hold. Add 1/2 inch (1.25 cm) for overlap.
Join Elastic: Overlap the ends of the elastic by 1/2 inch (1.25 cm) and stitch securely with a zigzag stitch to form a loop.
Attach Elastic: Divide your elastic loop and the raw waistband edge of your underwear into quarters and mark. Align these marks. Place the elastic against the wrong side of the waistband's raw edge, slightly stretching the elastic to fit the fabric as you sew. Use a zigzag stitch to attach the elastic.
Finish Waistband: Fold the elastic and the fabric edge towards the wrong side of the garment, so the elastic is now enclosed. Stitch again with a zigzag stitch, about 1/4 inch (0.6 cm) from the finished edge, stretching as you sew.
Your New Comfy Underwear!
And just like that, you've transformed an old knit top into a super comfy and custom-fit pair of underwear! This project is not only fun and sustainable but also leaves you with comfortable basics you'll actually love to wear.
Share your amazing underwear transformations with us in the comments or on social media! Happy sewing!
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