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I'm not a pro at this, but I have managed to whip out a few things that I'm not totally ashamed of. I figured I'd chronicle my latest project and post the process in case any sewing hobbyists want to take a crack at it. This is by no means an easy project for a first-timer, but it's not beyond the reach of anyone who has dealt with zippers and basic assembly before.
First, grab a chunk of cardboard and trace the inside triangle of your frame. I did not extend my shape all the way to the very front of the triangle since it gets so tight and it would be pointless. I then added a 3/8" seam allowance, and cut that shape out. The inner line is the triangle size, and the cut edge includes the seam allowance.
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Next I used the pattern on a rotary mat with a rotary cutter to cut the two side panels. I folded my fabric in half, pinned it together, and cut both sides at the same time.
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Next I cut the perimeter strips that will face the front triangle tubes. I used two fabrics: the outer layer that will show was a heavier Cordura, and the inner was the same as the side panels- a lighter nylon. The double layer was so that I could pad the inside of the panels along the down and seat tubes, and put a plastic stiffener along the top tube. I cut my strips 2 1/2" wide so that they would be just under 2" when finished, and just made them long with no particular size in mind. My tubes are around 1 1/2" in diameter.
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I sewed the strips wrongside to wrongside (back to back).
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I cut some strips of closed cell foam for the padding, and pulled it into the perimeter strips using some twine.
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Next I took the drive-side panel and sliced it in half where I wanted the zipper to go.
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Then it was time to incorporate the zipper into the panel.
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I compared the panel with the zipper to the opposite side to make sure they were still close in size.
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Now is a good time to decide on the placement of your velcro strips that will mount the bag on the bike.
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I started assembling the padded perimeter to the side panels starting at the front. I placed the pieces rightside to rightside making sure I didn't forget to include the velcro strips.
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Along the top I sewed an empty double panel that I will slide a plastic strip into later.
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For the stiffener strip I used an old plastic cutting board.
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The board was not long enough, so I overlapped two strips and stitched them together.
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At the forward end of the top panel I stitched a stop that the front end of the plastic will rest against.
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Next I added a couple of 2 inch strips of velcro to the side panels that can be joined in the finished product to form a vertical divider. They can be separated and lay flat when not in use by only sewing one edge of each.
![]()
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Next it was time to add the second side. I first pinned the velcro strips in place opposite the ones they will velcro against to mount the bag in the frame. You need pay attention to which way they need to face to engage the other side since things are a bit inside out at this point.
![]()
Next I drop the other panel in place and get ready to pin and sew it too.
![]()
I started at the hard area which for me was the curved bottom end. I'm not great at this to begin with, but I really suck at sewing around corners.
![]()
Then it was time to sew the top panel sides. The front end of the top panel was sewn shut, but I left the back end where it met the seat tube panel open. Don't forget to position your velcro frame mounting strips correctly.
![]()
Then I slide the plastic stiffener in the top panel from the open back end.
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Getting close now.
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Because the frame mounting velco strips tend to pull the zippers apart, I did add a backing piece of webbing to relieve the stress on the front end of the bag.
![]()
Finally I added a zig-zag stitch along the exposed edges as a salvage (I don't have a serger machine or any piping), turned it all right side out, and slapped it on the bike. Not too shabby.
![]()
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Go to it, peeps.
First, grab a chunk of cardboard and trace the inside triangle of your frame. I did not extend my shape all the way to the very front of the triangle since it gets so tight and it would be pointless. I then added a 3/8" seam allowance, and cut that shape out. The inner line is the triangle size, and the cut edge includes the seam allowance.
Next I used the pattern on a rotary mat with a rotary cutter to cut the two side panels. I folded my fabric in half, pinned it together, and cut both sides at the same time.
Next I cut the perimeter strips that will face the front triangle tubes. I used two fabrics: the outer layer that will show was a heavier Cordura, and the inner was the same as the side panels- a lighter nylon. The double layer was so that I could pad the inside of the panels along the down and seat tubes, and put a plastic stiffener along the top tube. I cut my strips 2 1/2" wide so that they would be just under 2" when finished, and just made them long with no particular size in mind. My tubes are around 1 1/2" in diameter.
I sewed the strips wrongside to wrongside (back to back).
I cut some strips of closed cell foam for the padding, and pulled it into the perimeter strips using some twine.
Next I took the drive-side panel and sliced it in half where I wanted the zipper to go.
Then it was time to incorporate the zipper into the panel.
I compared the panel with the zipper to the opposite side to make sure they were still close in size.
Now is a good time to decide on the placement of your velcro strips that will mount the bag on the bike.
I started assembling the padded perimeter to the side panels starting at the front. I placed the pieces rightside to rightside making sure I didn't forget to include the velcro strips.
Along the top I sewed an empty double panel that I will slide a plastic strip into later.
For the stiffener strip I used an old plastic cutting board.
The board was not long enough, so I overlapped two strips and stitched them together.
At the forward end of the top panel I stitched a stop that the front end of the plastic will rest against.
Next I added a couple of 2 inch strips of velcro to the side panels that can be joined in the finished product to form a vertical divider. They can be separated and lay flat when not in use by only sewing one edge of each.
Next it was time to add the second side. I first pinned the velcro strips in place opposite the ones they will velcro against to mount the bag in the frame. You need pay attention to which way they need to face to engage the other side since things are a bit inside out at this point.
Next I drop the other panel in place and get ready to pin and sew it too.
I started at the hard area which for me was the curved bottom end. I'm not great at this to begin with, but I really suck at sewing around corners.
Then it was time to sew the top panel sides. The front end of the top panel was sewn shut, but I left the back end where it met the seat tube panel open. Don't forget to position your velcro frame mounting strips correctly.
Then I slide the plastic stiffener in the top panel from the open back end.
Getting close now.
Because the frame mounting velco strips tend to pull the zippers apart, I did add a backing piece of webbing to relieve the stress on the front end of the bag.
Finally I added a zig-zag stitch along the exposed edges as a salvage (I don't have a serger machine or any piping), turned it all right side out, and slapped it on the bike. Not too shabby.
Go to it, peeps.
