How to Patch Insulated Carhartt Bib Overalls

We're finally getting the snow we've been waiting for and that means the Carhartt bibs were dragged out.  Last winter Nick spearheaded a campout which ended up being the coldest couple days of the entire winter.  Night temps were -10 F.  Day temps weren't much better.  In an attempt to keep warm the boys huddled around a giant fire they built in an old silo base.  Nick didn't realize just how close he was until someone pointed out that his bibs were burnt to a crisp.  It seemed every time the bibs were dry I didn't have time to repair the damage so here we are a year later and I finally took time to patch the burn holes.

I've made patches this way before and they're working well and holding up to the demands of boys.  Last year I patched the knees of Sam's Carhartt bibs - he loves the patches.  In case you find yourself in need of patching insulated bibs, here's my method for heavy duty, long lasting quilted patches.

This is what I had to work with.

First I measured the damaged area.  Then I added a couple of inches to my measurements.

I chose a heavyweight twill because I want these patches to be tough.  I cut a piece twice the width needed.  Then I cut a piece of batting and laid it inside the patch fabric.

I made a fabric/batting/fabric sandwich.

Using a long straight stitch, I quilted the patch in straight rows about 1 inch apart.

This is the quilted patch.  

I like patches to have rounded edges, so I folded the patch lengthwise and rounded the edge with sharp shears.

Then I laid it out to make sure it was going to work well.

I pinned it in place and used a heavy duty trade show clip to secure the bottom.  Since the bottom of overalls take a beating, I planned on folding the patch over the hem, but once I started sewing, I found it was just too thick.  I made an adjustment by trimming the bottom of the patch even with the hemline.  I double stitched along the lower edge and I think it turned out great.

Once pinned in place, set your machine to a wide zigzag, medium stitch length and stitch the patch in place, sewing about a 1/4 inch from the edge of patch.  This was kind of tricky because of the bulk of the overalls, but working slowly and pushing the extra pant leg through the sewing machine throat I was able to get it done.

Stitch a 2nd time all the way around the patch making sure the needle comes down right at the edge of the fabric.  Stitch a 3rd time along the bottom edge/hemline.  Trim any loose threads and you're done.....if your son only burned one leg, which mine didn't.  He burned them both so I did this process again making a quilted patch for the other leg.

Happy Patching!  And now he's ready for some serious sledding, snowmobiling, ice fishing, whatever the winter brings.

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