Thermal Iron Cover Tutorial

What do you do when you have to pack a hot curling iron? Well, my mother gave me a thermal cover for either a flat iron or curling iron and I thought it would be great to make some for my Sit and Sew ladies for Christmas. They make great gifts, or make one to keep in your suitcase. I studied it carefully and remade it my way. Here’s how I did it.

Getting Started

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Step 1. Supplies Needed:
– Tracing paper, medical paper or something to use as your pattern piece
– 1 Outer fabric approximately 10″ x 15″
– 1 Coordinating fabric for inside lining and outer bias binding (You can use purchased single fold bias tape if desired)
– 1 Small 10 x 15″ piece of Thinsulate or ironing board fabric with a heat barrier layer
– Ruler for drawing quilt lines
– Quilt guide that attaches to sewing machine (optional)
– Scissors
– Matching thread
– Chalk or disappearing marker

Sandwich three layers

Step 2. Layer and Draw:
– Layer the fabrics by sandwiching the Thinsulate between the two coordinating fabrics, with wrong sides to the Thinsulate.
– Pin
– Using your ruler, start drawing lines diagonally with your chalk or marker (whichever shows up best on your fabric) from one corner to the other. Continue drawing 1″ lines on either side of your original line until you have lines on the whole piece.

Draw One Inch Diagonal Quilt Lines

Sew Your Lines

Step 3. Sew Your Lines.
-Using a quilt guide attached to your foot, sew the 1″ diagonal lines across the entire piece. Feel free to sew the lines any way you wish as long as the layers are kept together. I chose 1″ diagonal because it was fast and easy.

Round Edges, Trace & Cut Out

Step 4. Pin, Trace and Cut.
-Take a pencil and round the edges of your 10″ x 15″ pattern piece. (It makes it easier to bind later). Trace around your quilted piece and cut out.

Get Ready to Baste

Step 5. Baste the Raw Edges
-Set your machine on baste and sew 1/8″ to 1/4″ around raw edge of quilted piece. This will prepare the edges for binding.

Cutting Sloppy Bias Strips

Step 6. How to Cut Some Sloppy Bias Strips
I know, I know. This is NOT how you make proper bias strips. Use a cutting mat and rotary cutter for pretty bias strips. I am giving you the quick-and-dirty to get this done. Remember, I know our sewing time is limited and we need to get these projects done pronto. Reduce the UFO’s. (Un-Finished Objects)
-Place fabric on grain and fold up one edge to a 45 degree. Insert your scissors on the fold and cut. This is what I call sloppy bias because it is fast and doesn’t use a ruler, cutting mat or rotary cutter. Remember: I shave off time if it works for me and gets me great results; otherwise, do it the right way. As you will see in the following steps, the sloppiness just disappears.

Piecing Bias Strips Together

Cut 1″-1.25″ strips from the chosen fabric for the binding. With right sides together, take two ends as shown. Stitch and press open. When you press these open, they should continue in a straight line, not a 90 degree angle. Cut off corner of one end of bias. Fold under 1/4″. Start pinning this to the bottom edge.

Attaching Bias Binding

Step 8. Bias Strip Attached to Edge
Starting at the lower edge, with right sides together (RST), align raw edges of bias binding and edges of thermal cover. Overlap the raw end of your ending bias strip (you may need to trim off a little) over the beginning folded edge. (The raw edge will be sandwiched between the folded edge and the thermal cover). Pin. Sew in a 1/4″ seam all the way around the outer edge. This is where some of the magic happens IF the sewing is straight and even.

Pink, Clip or Trim Seam Allowance

Step 9. Trim Edges.
Clip corners and trim around the entire thermal cover to reduce the seam allowance and allow for the bias to turn nicely around the corners. Press when flipped to underside.

Binding Pressed to Underside

Step 10. Magic Happening
Gently finger press the bias strip to the underside. It will naturally fold and curl on the corners. Turn raw edges in so that the fold is just covering the stitching line.

Steam a Seam to the Rescue!

Step 11. Making Life Easier
I used the 1/4″ Steam a Seam fusible tape on the trimmed seam allowance to help the folded bias edge stick until I can sew it down. Pin and press. On the right side, you should notice that the bias edge looks pretty good and is ready for some final decorative stitching.

Fancy Stitching

Step 12 Pick a Favorite Stitch

Time for Tacos

Step 13. Fold In Half
You are almost done! Fold in half so it looks like a taco. Pin in the ditch of the stitching, trying to match up your binding stitching lines from both sides. You will then ‘stitch in the ditch’ through all layers in a straight seam from the bottom up to the top leaving an opening 2″-3″ from the top edge. This will leave the opening for your curling iron or flat iron.