The Basic Process for Installing a Pillow Zipper
Sewing a zipper into a pillow cover takes about 30 to 45 minutes once you have the materials ready. You cut an opening in the back or side of the pillow fabric, pin the zipper behind that opening so the teeth face inward, and stitch it down on all four sides using a zipper foot on your machine. The zipper then sits hidden inside the seam, and when you open it, the pillow insert slides in and out.
The most common mistake is stitching too close to the zipper teeth, which jams the slider or breaks the thread. Keeping a consistent quarter-inch distance from the teeth prevents this. The second mistake is not securing the zipper ends before you start stitching, which causes the fabric to shift as you sew.
Key Takeaways
- Cut your opening on the back or side seam of the pillow, typically 12 to 16 inches long depending on your pillow size, and leave a half-inch seam allowance on all sides.
- Pin the zipper face-down behind the opening so the teeth face the inside of the pillow, then use a zipper foot to stitch a quarter-inch from the teeth on all four sides.
- Stitch the zipper ends closed by hand or machine before you attach the zipper foot, so the fabric does not slip during the main seam.
- Test the zipper by opening and closing it several times before you insert the pillow form, because fixing a jammed zipper after the pillow is stuffed is difficult.
Choosing Where to Put the Zipper Opening
The zipper opening usually goes on the back of the pillow or along one side seam. Back openings are easier to hide because the back faces the wall or furniture. Side openings are faster to cut and sew but more visible when the pillow is displayed.
Measure your pillow form and make the opening about 2 inches shorter than the form's width or length. A 16-inch pillow form gets a 14-inch opening; an 18-inch form gets a 16-inch opening. This leaves enough fabric on either end to anchor the zipper securely and prevents the opening from gaping when the pillow is stuffed.
Mark the opening with tailor's chalk or a fabric pen before you cut. Measure from the edge of the fabric to find the center line, then mark the opening length on that line. This keeps the opening centered and symmetrical.
Cutting and Preparing the Fabric
Cut the opening with sharp fabric scissors or a rotary cutter, cutting straight through both layers if you are working with two pieces of fabric pinned together. Cut only the opening itself—do not cut the seam allowance around it. You need that half-inch border of fabric on all sides to stitch the zipper down.
If you are sewing a zipper into an already-assembled pillow cover, use a seam ripper to carefully open the existing seam along your marked opening line. Remove the thread completely so the fabric lies flat. Press the opening flat with an iron to remove wrinkles and creases, which makes pinning the zipper much easier.
Cut a piece of lightweight fusible interfacing slightly larger than your opening and iron it to the back side of the fabric around the opening. This stabilizes the fabric and prevents it from stretching or fraying as you sew. Let it cool completely before you move to the next step.
Pinning and Positioning the Zipper
Lay the pillow fabric flat with the right side facing up. Place the zipper face-down on top of the opening so the zipper teeth run parallel to the opening and the zipper pull faces away from you. The zipper should sit centered over the opening with equal fabric on both sides.
Pin the zipper in place along both long edges, using pins perpendicular to the zipper so they do not interfere with the presser foot. Space pins about 2 inches apart. Flip the fabric over and check that the zipper is centered from the back side as well. Adjust if needed before you sew.
find the zipper ends by hand-stitching or machine-stitching a small box around each end of the zipper, about half an inch from the zipper stop. This prevents the fabric from shifting when you attach the zipper foot and begin the main seam. Use thread that matches the zipper or the fabric.
Stitching the Zipper Down
Install the zipper foot on your sewing machine according to your machine's manual. The zipper foot is narrower than a standard presser foot and allows you to stitch close to the zipper teeth without hitting them. Thread your machine with thread that matches the pillow fabric or the zipper.
Stitch along one long side of the zipper, keeping the needle a quarter-inch away from the teeth. Sew slowly and stop frequently to check your distance. When you reach the zipper pull, stop with the needle down, raise the presser foot, slide the zipper pull past the needle, lower the presser foot, and continue stitching. Do not try to sew over the zipper pull.
Stitch the other long side of the zipper the same way, again keeping a quarter-inch distance from the teeth. Then stitch across both short ends of the zipper, about half an inch from the zipper stops. These short seams lock the zipper in place and prevent it from sliding out of the opening.
Backstitch at the beginning and end of each seam to lock the thread. Remove the pins and open and close the zipper several times to make sure it moves smoothly. If the slider jams, stop when ready and check for thread caught in the teeth or stitches too close to the teeth.
Finishing the Pillow Cover
Once the zipper is sewn in, you can assemble the rest of the pillow cover. If you cut the opening in a single layer of fabric, pin the front and back pieces together with right sides facing and sew around all four sides, leaving the zipper opening unsewn. If you opened an existing seam to insert the zipper, sew the rest of the seams closed, again leaving the zipper opening alone.
Trim the corners diagonally about a quarter-inch from the stitching to reduce bulk when you turn the cover right-side out. Clip the curves if your pillow is round or has rounded corners. Turn the cover right-side out through the zipper opening, pushing the corners out fully with a point turner or chopstick.
Press the cover with an iron, paying special attention to the seams and the zipper opening. Insert the pillow form through the zipper opening and close the zipper. The zipper should sit flush with the fabric and not pucker or pull.
Troubleshooting Common Problems
The zipper jams or does not slide smoothly. Stop sewing when ready and check for thread caught in the teeth. Use a seam ripper to remove any stitches that are too close to the teeth. If the zipper itself is damaged, you may need to remove it and install a new one. Rub the teeth lightly with a graphite pencil to lubricate them before you try again.
The fabric puckers around the zipper. This usually means the fabric was stretched as you pinned or sewed. Remove the stitches, repin the zipper without pulling the fabric, and sew again more slowly. Use your hands to guide the fabric gently rather than letting the machine feed it.
The zipper opening gapes or does not close evenly. The opening may be too long for your pillow form, or the zipper may not be centered. If the opening is too long, you can hand-stitch the excess fabric closed on either side of the zipper. If the zipper is off-center, you will need to remove it and reposition it.
The zipper pull breaks or the slider stops working. Replace the entire zipper. Remove all stitches with a seam ripper, slide the old zipper out, and install a new one of the same length and type. This takes about 20 minutes and is much faster than trying to repair a broken slider.
Frequently Asked Questions
What size zipper do I need for my pillow?
Measure the opening you plan to cut and buy a zipper that is 1 to 2 inches longer than that opening. A 14-inch opening needs a 16-inch or 18-inch zipper. The extra length gives you room to anchor the zipper ends and prevents the slider from running off the end of the teeth.
Can I use a regular presser foot instead of a zipper foot?
You can, but it is much harder to keep a consistent distance from the zipper teeth, and you risk stitching too close and jamming the slider. A zipper foot costs $5 to $15 and works on most machines. It is worth buying if you plan to sew more than one zipper.
What type of zipper works best for pillows?
Coil zippers are softer and quieter than metal zippers and work well for decorative pillows. Metal zippers are more durable and better for pillows that get heavy use. Both types come in various lengths. Choose a color that matches your fabric or go with black or white, which work with most colors.
Do I have to open the zipper before I turn the pillow cover right-side out?
Yes. If the zipper is closed when you turn the cover, the fabric will bunch and tear. Open the zipper at least halfway before you turn the cover, and use the opening to push the corners out and turn the fabric right-side out.
Can I sew a zipper on a pillow that is already stuffed?
No. The pillow form will be in the way and will get damaged by the needle. Always insert the zipper before you stuff the pillow. If you need to add a zipper to an already-stuffed pillow, you will have to remove the form first.