Step by Step Instructions for Protective Underwear Assembly
Patterns Courtesy of Transformation Textiles. Used with Permission.
All are free to share widely with any person who would like a copy.
FACILITATOR NOTES
1. Before Starting
Do not start cutting or sewing yet
First show each step slowly with process sample
Make sure everyone sees the process before action begins
One t-shirt can make protective underwear + other things
Plan first — no random cutting
2. Preparation & Cutting from T-Shirt
Lay the whole t-shirt flat
Check front and back
Plan before cutting — place pattern pieces first
Cut side seams completely to open the shirt flat
Keep sleeves — they are useful extra fabric
3. Tracing Safely (Without Damaging the Table)
Protect the table with plastic or folder
Do small dots — not long marker lines (Easier & saves ink)
When cutting, cut just INSIDE the dots so no ink shows on finished product
Final underwear will then have no marker showing
4. Join Front + Back (Tip: Remember keep sides “Good to Good”)
Place front + back pieces face to face (good side touching good side)
Stitch only the middle curve — 1 cm seam allowance
Open the joined pieces, now the good side is on the outside
5. Make the Inner Protective Gusset
Use waterproof or towel fabric as the core
Place core centered on cotton top piece
Cotton must be 1 cm bigger all around
Stitch both top edges together (waterproof & cotton) close to the edge
Pull waterproof to the other bottom edge of cotton — stitch together close to the edge
Turn inside out — top and bottom have a clean edge
Now stitch along the open curved edge of waterproof to keep it flat and secured to cotton layer
6. Attach Security Bands (for pad/liner)
Cut bands from t-shirt hem (turn hem inside out to get ½ cm band)
Front band = 2 fingers from top
Back band = 3 fingers from back
Space between reinforcing stitches = 4 fingers
(this is where the liner will go between the bands)
Space between front and back bands ≈ one hand length
Attach bands to edge with reinforcing stitches, for the back band, adding additional reinforcing stitches to accommodate only the 4 fingers space for liner will prevent liner shifting during wear
7. Attach Gusset - “Good to Good”
Put good side (gusset with bands) to good side (outer face) of underwear
Ensure placement of the gusset follows the underwear’s leg curve
Ensuring the cotton gusset layer and the underwear leg curves are matching together, stitch together, but avoid stitching through the waterproof part of gusset
Then pull the gusset to the other leg curve and repeat
Turn inside out — now the gusset is on the inside of underwear
8. Close Sides + Finish Waist
Sew side seams — 1 cm width seam allowance
Open seam flat inside (no folding to one side)
Fold waist down 1 thumb-length down
Sewing 1/2 cm beside the seam down, turn at bottom, and back up the other side
No elastic needed — hip fit design
Side Seams & Waistband Finish
Sew side seams using a 1 cm seam allowance.
Open and flatten the seam for a smooth, professional finish.
Fold the waistband down using one thumb-length as the measuring guide.
Stitch down and back up again to fully secure the waistband.
9. Finish
Confirm smooth outside and clean inside
Underwear is comfortable, durable, washable, safe
Encourage sharing and training others with this skill, as it brings dignity and hope.
