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Installing A Main Zipper In Your Patagonia Down Jacket

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  1. Installing A Main Zipper In Your Patagonia Down Jacket, Main Zipper: step 1, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket, Main Zipper: step 1, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket, Main Zipper: step 1, image 3 of 3
    • Unzip the jacket and fold back the bottom corner.

    • Identify the start of the seam that is holding the zipper in place.

  2. Installing A Main Zipper In Your Patagonia Down Jacket: step 2, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 2, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 2, image 3 of 3
    • Using a seam ripper, gently remove the stitches on the inside of the zipper.

    • Be careful not to accidentally puncture or tear the jacket.

  3. Installing A Main Zipper In Your Patagonia Down Jacket: step 3, image 1 of 2 Installing A Main Zipper In Your Patagonia Down Jacket: step 3, image 2 of 2
    • Bend the zipper teeth away from the zipper webbing to make it easier to reach the stitches that hold the zipper and webbing together.

    • Using the seam ripper, gently rip the seam between the zipper and zipper webbing.

  4. Installing A Main Zipper In Your Patagonia Down Jacket: step 4, image 1 of 2 Installing A Main Zipper In Your Patagonia Down Jacket: step 4, image 2 of 2
    • Continue ripping the seam holding the zipper to the webbing until you come to the top of the seam.

  5. Installing A Main Zipper In Your Patagonia Down Jacket: step 5, image 1 of 2 Installing A Main Zipper In Your Patagonia Down Jacket: step 5, image 2 of 2
    • When you come to the fold in the zipper webbing, insert the seam ripper between the two layers of webbing, and gently pull the stitches out.

  6. Installing A Main Zipper In Your Patagonia Down Jacket: step 6, image 1 of 1
    • The zipper should now be free from the jacket and can be discarded.

  7. Installing A Main Zipper In Your Patagonia Down Jacket: step 7, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 7, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 7, image 3 of 3
    • Identify where the zipper flap is still sewn into the jacket. Use the seam ripper to free the zipper flap from the jacket. The yellow rectangle in the photos above will help you identify the zipper flap.

    • Be careful not to damage the jacket with the seam ripper as you free the webbing.

  8. Installing A Main Zipper In Your Patagonia Down Jacket: step 8, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 8, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 8, image 3 of 3
    • Lay the jacket flat and measure from the base of the zipper to the collar, along the seam you just removed. In our case we measured 27 inches.

    • The jacket should be flat, so you get an accurate measurement.

  9. Installing A Main Zipper In Your Patagonia Down Jacket: step 9, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 9, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 9, image 3 of 3
    • Lay out your new zipper on a flat surface and use the measurement you recorded in the step above, starting from the zipper box, or the bottom of the zipper.

    • Mark the measurement with tailor's chalk.

    • Pull the zipper slider back behind the mark you just made.

  10. Installing A Main Zipper In Your Patagonia Down Jacket: step 10, image 1 of 2 Installing A Main Zipper In Your Patagonia Down Jacket: step 10, image 2 of 2
    • Measure one inch beyond where you just marked and make a second mark with tailor’s chalk.

  11. Installing A Main Zipper In Your Patagonia Down Jacket: step 11, image 1 of 2 Installing A Main Zipper In Your Patagonia Down Jacket: step 11, image 2 of 2
    • Cut the zipper between the teeth at the second mark you made.

  12. Installing A Main Zipper In Your Patagonia Down Jacket: step 12, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 12, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 12, image 3 of 3
    • Use end nipper pliers to remove the teeth of the zipper between the two marks.

    • Use needle-nose pliers to remove all the leftover bits of the teeth from the zipper.

  13. Installing A Main Zipper In Your Patagonia Down Jacket: step 13, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 13, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 13, image 3 of 3
    • Take a zipper stop and align it, posts down, just beyond the last remaining zipper tooth.

    • Crimp the zipper stop onto the zipper using pliers.

  14. Installing A Main Zipper In Your Patagonia Down Jacket: step 14, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 14, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 14, image 3 of 3
    • Fold the excess zipper tape away from the teeth at a slight angle.

    • Sew the toothless end of the zipper down, backstitching to hold it in place.

  15. Installing A Main Zipper In Your Patagonia Down Jacket: step 15, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 15, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 15, image 3 of 3
    • Align the toothless edge of the zipper with the inside serged edge of the zipper webbing.

    • The serged edge is the one with the zig-zag stitching.

    • Fold the top of the webbing down over the sewn zipper tape.

    • You can pin the zipper and webbing in place for more stability.

  16. Installing A Main Zipper In Your Patagonia Down Jacket: step 16, image 1 of 2 Installing A Main Zipper In Your Patagonia Down Jacket: step 16, image 2 of 2
    • Align the zipper and webbing in the sewing machine so that the zipper teeth are along the edge of the presser foot.

    • Sew a few stitches, removing pins before you come to them.

  17. Installing A Main Zipper In Your Patagonia Down Jacket: step 17, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 17, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 17, image 3 of 3
    • Sew along the edge of the zipper teeth, making sure that the zipper and webbing stay aligned.

  18. Installing A Main Zipper In Your Patagonia Down Jacket: step 18, image 1 of 2 Installing A Main Zipper In Your Patagonia Down Jacket: step 18, image 2 of 2
    • Reinsert the zipper and webbing into the jacket, aligning the edge of the jacket fabric with the zipper teeth.

  19. Installing A Main Zipper In Your Patagonia Down Jacket: step 19, image 1 of 2 Installing A Main Zipper In Your Patagonia Down Jacket: step 19, image 2 of 2
    • While holding the zipper in place, move the fabric underneath the zipper out of the way so you’re only sewing the zipper to one layer of fabric.

  20. Installing A Main Zipper In Your Patagonia Down Jacket: step 20, image 1 of 2 Installing A Main Zipper In Your Patagonia Down Jacket: step 20, image 2 of 2
    • Install the zipper foot into your sewing machine.

    • Align the jacket and zipper in the sewing machine.

    • Be sure that there is no fabric behind the zipper webbing before you sew.

  21. Installing A Main Zipper In Your Patagonia Down Jacket: step 21, image 1 of 2 Installing A Main Zipper In Your Patagonia Down Jacket: step 21, image 2 of 2
    • Check your alignment and begin sewing, guiding the fabric along the zipper teeth.

    • Go slowly, re-aligning the fabric as you go.

  22. Installing A Main Zipper In Your Patagonia Down Jacket: step 22, image 1 of 2 Installing A Main Zipper In Your Patagonia Down Jacket: step 22, image 2 of 2
    • Continue sewing and re-aligning the zipper as you proceed along the full length of the zipper.

  23. Installing A Main Zipper In Your Patagonia Down Jacket: step 23, image 1 of 1
    • When you reach the end of the zipper, backstitch to hold your stitches in place and remove the jacket from the sewing machine.

  24. Installing A Main Zipper In Your Patagonia Down Jacket: step 24, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 24, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 24, image 3 of 3
    • Align the inside jacket fabric along the backside of the webbing.

    • Try to align the stitch holes directly over the stitches you just sewed.

  25. Installing A Main Zipper In Your Patagonia Down Jacket: step 25, image 1 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 25, image 2 of 3 Installing A Main Zipper In Your Patagonia Down Jacket: step 25, image 3 of 3
    • Align the jacket in the sewing machine, with the zipper webbing facing up.

    • Holding the inside fabric of the jack in place, sew directly over the original stitching.

    • Go slowly, re-aligning the fabric as you go.

    • Clip the threads, and admire your work!

    • Repeat this guide, ironing the webbing when you’re finished, to install the other side of the zipper.

Finish Line

10 other people completed this guide.

Brittany McCrigler

Member since: 03/05/12

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131 Guides authored

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3 Comments

Very well documented.

Mike Macey - Reply

Have not yet completed my zipper repair very good tutorial. Thanks

mildred Norton - Reply

Well done, thank you so much. I was worried about the down falling out after I rip the old zipper, but I see that isn't a problem!

Js W - Reply

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