This is a fantastic project that turns unusable denim scraps into a highly functional and durable item. Denim’s ruggedness makes it perfect for a cosmetic bag, and using the textures and seams from old jeans gives the pouch character.

This long-form tutorial will guide you through sewing a small, boxy denim pouch that is ideal for cosmetics, pencils, or small electronics.

Upcycled From Old Jeans – Full Sewing Pattern & Step-by-Step Guide

Recycling old jeans is one of the most satisfying sewing projects: the denim is durable, stylish, and full of character. A mini pouch or cosmetic bag made from jeans is perfect for storing makeup, coins, earbuds, or small essentials.
This tutorial will walk you through creating a beautifully structured mini pouch using simple techniques—ideal for beginners and experienced sewists alike.

MATERIALS NEEDED

Fabric & Notions

Scrap pieces of old denim jeans (preferably medium-weight)
Cotton fabric for lining (fat quarter is enough)
Zipper: 7–9 inch (18–22 cm) nylon or metal zipper
Matching thread (polyester recommended)
Optional: fusible interfacing or fusible fleece (for added structure)
Fabric scissors or rotary cutter
Pins or clips
Sewing machine (standard straight stitch is enough)
Iron & ironing board
Tailor’s chalk or washable marker
Ruler or measuring tape

FINISHED SIZE

Approx.: 7″ wide × 4″ tall × 2″ deep
If you want a different size, simply adjust the rectangle dimensions.

CUTTING PATTERN (With Measurements)

Main Bag Panels (Denim):

Cut 2 rectangles measuring:

8.5” × 6.5” (22 cm × 17 cm)

Lining Fabric:

Cut 2 rectangles:

8.5” × 6.5”

Optional Interfacing:

Cut 2 rectangles the same size as the denim pieces.

Zipper Tabs (Optional but Recommended):

Cut 2 small rectangles:

1.5” × 2” (4 cm × 5 cm)
These create a clean, professional finish at the ends of your zipper.

STEP-BY-STEP SEWING INSTRUCTIONS

STEP 1 – PREPARE THE DENIM PIECES

Lay your old jeans flat.
Select a section free from heavy seams.
Cut two panels slightly bigger than the final dimensions, then trim accurately.
If your denim is thick, lightly press it with steam to flatten.
Apply fusible interfacing to the wrong side of each denim piece if you want extra structure.

Tip: Reuse pockets, seams, or faded sections of jeans for a more stylish look!

STEP 2 – PREPARE THE ZIPPER AND TABS

If using zipper tabs:

Fold each small rectangle in half, right sides together, and press.
Insert one zipper end into the folded tab.
Sew across to secure.
Trim the tab so it aligns with the width of your bag panels.

Zipper tabs create a neat, store-bought finish and prevent bulky edges.

STEP 3 – INSTALL THE ZIPPER (Sandwich Method)

This is the most important and neatest technique.

Lay one denim panel right side up.
Place the zipper right-side down on top of the edge.
Place the lining fabric right-side down on top of the zipper, forming a “fabric-zipper sandwich.”
Clip in place.
Sew using a zipper foot, ¼” seam allowance.
Turn both fabrics right-side out and press.

Repeat for the other side:

Lay the second denim panel right side up.
Place the zipper (with attached layers) right side down.
Add the lining on top, right side down.
Sew the second side.
Turn and press again.

Tip: Open the zipper halfway before sewing the bag closed later.

STEP 4 – TOPSTITCH AROUND THE ZIPPER

Topstitching keeps the lining away from the zipper teeth and adds a professional look.

Sew 1⁄8″ from the zipper edge.
Go slowly to keep the line straight.
Use a slightly longer stitch (3.0–3.5 mm) for a clean finish.

STEP 5 – ASSEMBLE THE BAG BODY

1. Align the Panels

Open up the layers so the denim panels face each other (right sides together).
Lining pieces face each other too (right sides together).
Match edges carefully.
Pin or clip around the entire perimeter.

2. Match the Seams by the Zipper

Press seam allowances toward the lining.
This reduces bulk near the zipper.

3. Leave a Gap in the Lining

Mark a 3–4 inch opening at the bottom of the lining fabric.
This is where you’ll turn the pouch right side out.

4. Sew Around the Bag

Sew all around with a ¼” to ⅜” seam allowance, except the turning gap.

Reinforce the corners with a few backstitches.

STEP 6 – CREATE BOXED CORNERS (Optional but Recommended)

Boxed corners help your pouch stand upright.

Pinch each corner so the side seam aligns with the bottom seam, forming a triangle.
Measure 1 inch (2.5 cm) from the tip.
Draw a line straight across.
Stitch along this line.
Trim off the triangle, leaving ¼” seam allowance.

Repeat on all four corners (2 denim, 2 lining).

STEP 7 – TURN THE BAG RIGHT SIDE OUT

Carefully turn the pouch through the lining opening.
Push out the corners using a blunt tool (e.g., chopstick).
Once everything looks correct, tuck in the edges of the lining opening.
Sew the opening closed using:
- A straight stitch by machine, or
- A ladder stitch by hand for an invisible finish.

STEP 8 – FINAL SHAPING & PRESSING

Press the pouch gently, especially around the zipper.
Avoid pressing denim on high heat if it contains elastic fibers.
Reshape the corners so the bag stands correctly.

OPTIONAL EMBELLISHMENTS

Add a Denim Pocket

Use a small pocket from the jeans and stitch it onto the front panel for a rustic look.

Add Jeans Labels or Tags

Original leather or canvas jean labels make great statement pieces.

Decorative Stitching

Use heavy topstitch thread for the classic “jeans look.”

Add a Wrist Strap

Cut a denim strip 1″ × 10″, fold in thirds, topstitch, and attach with a small loop.

TROUBLESHOOTING TIPS

Problem: Denim too thick at seams

→ Use a jeans needle (size 90/14 or 100/16).
→ Sew slowly and flatten seams with a hammer.

Problem: Zipper puckering

→ Reduce presser foot pressure.
→ Press the sandwich before sewing.

Problem: Bag lining gets caught in the zipper

→ Topstitch closer to zipper teeth.
→ Ensure lining is pressed away from zipper before sewing.

PATTERN VARIATIONS

1. Flat Rectangular Pouch (No Box Corners)

Skip boxed corners for a slim pencil pouch style.

2. Triangle or Pyramid Pouch

Use shorter sides and add a loop at the top.

3. Patchwork Denim Version

Use small denim scraps to create a quilted exterior.

4. Quilted & Padded Version

Add fusible fleece for a soft, cosmetic-bag style finish.

SUMMARY

This upcycled denim mini pouch/cosmetic bag is a quick and satisfying project that uses materials you already have. With just a few basic sewing skills—installing a zipper, sewing a straight seam, and optional corner boxing—you can create a durable, stylish, practical pouch.

Perfect as:

Makeup bags
Travel organisers
Coin pouches
Gifts
Craft storage bags

Using old jeans makes each pouch unique and environmentally friendly.