Introduction

For replacement parts or further assistance, contact Patagonia Customer Service.

While we have friends who’s jackets are held together with duct tape, it’s far more effective, not to mention easier when it comes time to change layers, to simply replace a broken zipper in your fleece jacket. Here’s how.This guide will walk you through the steps necessary to replace the zipper in your Patagonia fleece jacket. We’ll be using a Bernina 830 sewing machine, but the procedure should be similar on most machines with a mechanical stitch width dial. Check your owner’s manual for instructions specific to your machine. In this guide we’ll be using contrasting thread for visibility. When it comes time to do your actual repair, you’ll want to use thread that matches the color of your fabric.

Video Overview

Patagonia fleece repair overview.

Image 1/2: Fold open the bottom corner of the jacket. Image 2/2: Fold open the bottom corner of the jacket.
  • Lay your jacket face-up onto a flat surface like a table. Unzip the zipper as much as possible.

  • Fold open the bottom corner of the jacket.

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Image 1/3: Image 2/3: Image 3/3:
  • Rip the seam that holds the zipper in place. This is the outside seam of the two rows of stitching.

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  • Start ripping the inside seam.

  • Rip only a few of the stitches.

  • Be sure to avoid ripping the serged edge. To do this, start the blade pointing away from the serge seam.

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Image 1/3: Pull the zipper webbing away from the teeth of the zipper. Image 2/3: Rip the stitches holding the webbing to the zipper. Image 3/3: Rip the stitches holding the webbing to the zipper.
  • After you have ripped a few stitches, fold the jacket closed again.

  • Pull the zipper webbing away from the teeth of the zipper.

  • Rip the stitches holding the webbing to the zipper.

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Image 1/3: Both the zipper webbing and zipper should now be free from the jacket. Image 2/3: Repeat steps 1-5 on the other side of the zipper. The second side may or may not have webbing. Image 3/3: Repeat steps 1-5 on the other side of the zipper. The second side may or may not have webbing.
  • At the top of the zipper there will be an area where the collar is folded back over itself. Rip out the outermost seam holding the zipper webbing in place.

  • Both the zipper webbing and zipper should now be free from the jacket.

  • Repeat steps 1-5 on the other side of the zipper. The second side may or may not have webbing.

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Image 1/2: [[Sewing Glossary#Section_Measuring_Tape|Measure]] the same length on your zipper from the zipper stop up. Mark this with tailor’s chalk. Image 2/2: Measure two inches above that line and make a second mark with your tailor’s chalk.
  • Lay your jacket out, holding it to full length but not stretched. Measure from the top of the collar to waist.

  • Measure the same length on your zipper from the zipper stop up. Mark this with tailor’s chalk.

  • Measure two inches above that line and make a second mark with your tailor’s chalk.

  • Cut the zipper at the first mark you made. Be sure to cut between the teeth of the zipper to preserve your scissors.

  • Be sure that the zipper slider is below your first mark so you don't cut it off!

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  • Use end nipper pliers to cut off all of the zipper teeth above the first mark.

  • Cut the teeth in half, and then remove the back half with your fingers.

  • Remove two teeth below the mark on one side.

  • Repeat this step on the other side of the zipper, removing three teeth below the mark instead of two.

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Image 1/3: Crimp the zipper stop into place using pliers. Image 2/3: Repeat this step on the second side of the zipper. Image 3/3: Repeat this step on the second side of the zipper.
  • Place the zipper stop directly above the last tooth on the zipper. Be sure you get all the way around the zipper.

  • Crimp the zipper stop into place using pliers.

  • Repeat this step on the second side of the zipper.

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Image 1/3: Image 2/3: Image 3/3:
  • Take the side of the zipper that had webbing, and fold the excess zipper tape on the end of the zipper away from the zipper teeth at a slight angle.

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Image 1/3: Tack the fold into place with a few stitches. Image 2/3: Tack the fold into place with a few stitches. Image 3/3: Tack the fold into place with a few stitches.
  • Place the folded zipper end into the sewing machine.

  • Tack the fold into place with a few stitches.

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Image 1/2: Repeat steps 9-11 on the other side of the zipper. Image 2/2: Repeat steps 9-11 on the other side of the zipper.
  • Clip the threads on the zipper.

  • Repeat steps 9-11 on the other side of the zipper.

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Image 1/3: Place the top of the zipper in the crease of the fold of the webbing at the collar. Image 2/3: Place the top of the zipper in the crease of the fold of the webbing at the collar. Image 3/3: Place the top of the zipper in the crease of the fold of the webbing at the collar.
  • Take the side of the zipper that had the webbing, and lay it back into the webbing, aligning the zipper tape edge along the serged edge of the webbing.

  • Place the top of the zipper in the crease of the fold of the webbing at the collar.

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  • Fold the top of the zipper webbing over the zipper at the crease of the collar.

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Image 1/2: Image 2/2:
  • Pin the folded zipper webbing in place.

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Image 1/2: The serged edge is the edge with the, overlock, or zigzag stitching. Image 2/2: The serged edge is the edge with the, overlock, or zigzag stitching.
  • Pin the length of the zipper to the webbing, making sure that the zipper tape edge is still aligned with the serged edge of the webbing.

    • The serged edge is the edge with the, overlock, or zigzag stitching.

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Image 1/2: Sew the zipper onto the webbing. Image 2/2: Sew the zipper onto the webbing.
  • Position the webbing and zipper in the sewing machine 1/4 of an inch from the zipper teeth on the side of the zipper tape.

  • Sew the zipper onto the webbing.

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Image 1/3: Image 2/3: Image 3/3:
  • While you’re sewing, remove the pins as you come to them. Running them over with your machine may break your needle.

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Image 1/2: Cut the threads, and free the zipper and webbing from the sewing machine. Image 2/2: Cut the threads, and free the zipper and webbing from the sewing machine.
  • Backstitch at the end of the zipper to prevent the seam from unraveling.

  • Cut the threads, and free the zipper and webbing from the sewing machine.

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Image 1/2: Sandwich the top of the zipper and webbing in between the two layers as you would see it when it is finished. Image 2/2: Align the top of the webbing with the border between the fleece and the start of the same type of fabric as the webbing, about 1/4 inch below the edge of the collar.
  • Take the jacket collar and open the folded section that you ripped out in step 6.

  • Sandwich the top of the zipper and webbing in between the two layers as you would see it when it is finished.

  • Align the top of the webbing with the border between the fleece and the start of the same type of fabric as the webbing, about 1/4 inch below the edge of the collar.

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Image 1/3: Holding the backside of the collar fabric in place, turn the collar back to the front side. Image 2/3: Holding the backside of the collar fabric in place, turn the collar back to the front side. Image 3/3: Holding the backside of the collar fabric in place, turn the collar back to the front side.
  • Fold the backside of the collar fabric over the webbing that covers the zipper seam.

  • Holding the backside of the collar fabric in place, turn the collar back to the front side.

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Image 1/2: Continue pinning the webbing and zipper to the inside of the jacket, along the seam you originally ripped. Image 2/2: Continue pinning the webbing and zipper to the inside of the jacket, along the seam you originally ripped.
  • Still holding the zipper and webbing between the two layers of collar fabric, pin the layers in place.

  • Continue pinning the webbing and zipper to the inside of the jacket, along the seam you originally ripped.

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Image 1/2: Image 2/2:
  • When you come to the jacket's waist, sandwich the webbing and zipper between the folded edge at the waist.

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Image 1/2: Sew the edge of the fleece to the jacket as close to the edge as possible. Image 2/2: Be sure to backstitch at each end of the seam.
  • Change the presser foot to the zipper foot.

  • Sew the edge of the fleece to the jacket as close to the edge as possible.

  • Be sure to backstitch at each end of the seam.

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Image 1/2: Backstitch at both ends of the seam. Image 2/2: Backstitch at both ends of the seam.
  • Topstitch the fleece to the zipper 1/4 inch from the zipper.

  • Backstitch at both ends of the seam.

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Image 1/2: Align the zipper at the waist of the jacket, sandwiching the zipper into the waist as necessary. Image 2/2: Align the zipper at the waist of the jacket, sandwiching the zipper into the waist as necessary.
  • Sandwich the second side of the zipper in the collar just as you did the first side. This side will not have webbing.

  • Align the zipper at the waist of the jacket, sandwiching the zipper into the waist as necessary.

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Image 1/1:
  • Align the second side of the zipper at the border of the fleece (or any other fabric like a wind resistant material) about a quarter of an inch below the top edge of the collar, as you did on the previous side.

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Image 1/2: Pin the second side of the zipper in place. Image 2/2: Pin the second side of the zipper in place.
  • Check that the zipper is sandwiched in the collar as on the other side.

  • Pin the second side of the zipper in place.

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Image 1/3: As before, sew the zipper into place very close to the edge. Image 2/3: As before, sew the zipper into place very close to the edge. Image 3/3: As before, sew the zipper into place very close to the edge.
  • Replace the zipper foot in your machine.

  • As before, sew the zipper into place very close to the edge.

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Image 1/2: Clip threads, check out your work, and give yourself a pat on the back. Image 2/2: Clip threads, check out your work, and give yourself a pat on the back.
  • Topstitch the second side as before.

  • Clip threads, check out your work, and give yourself a pat on the back.

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Conclusion

To reassemble your device, follow these instructions in reverse order.

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Brittany McCrigler

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