How to Sew the Whale Zipper Pouch with HeatnBond Support

Hello friends! I'm so excited to share this sweet and simple project with you today: the Whale Zipper Pouch. This fully lined, curved pouch is a cheerful make that’s perfect for storing crayons, snacks, small toys, or travel essentials. It’s also a great project to build confidence with zipper installation, shaped seams, and structured finishing. Using ThermoWeb products helps the pouch keep its shape while adding softness and stability in all the right places.

Materials You’ll Need

Fabric & Pattern:

• Fat eighths or scraps from the Created With Love fabric collection by Jennifer Long for Riley Blake Designs
• Whale Zipper Pouch PDF Pattern (available through the Sew A Story Pattern Club) 

ThermoWeb Products:

• HeatnBond Fusible Fleece – Used on the body, tail, and belly to add structure and softness
• HeatnBond Craft Extra Firm Fusible – Provides strength and durability in the tail and fins 

Notions & Tools:

• 9" zipper
• 1/4" grommet
• Coordinating thread
• Basic sewing supplies (scissors, rotary cutter, clips, etc.)
• Quilty™ Hemostat – For turning and shaping curved pieces 

Step-by-Step Instructions

1. Fuse Your Fabric

Apply HeatnBond Fusible Fleece to the wrong side of the pouch’s back, sides, belly, and tail fabrics. Fuse according to ThermoWeb’s instructions using firm, dry heat and a press cloth. Next, apply HeatnBond Craft Extra Firm Fusible to the fin and tail pieces where added structure is needed. This keeps those smaller elements crisp and shapely.

2. Cut & Trace

Using the pattern templates, trace and cut all required shapes. Be sure to note which pieces need to be reversed. Carefully mark all notches and placement dots to guide assembly.

3. Make the Tail and Fins

Place fin pieces right sides together. Sew around the outer edges, leaving the straight edge open. Clip curves, turn right side out using the Quilty Hemostat, then press and topstitch. Repeat for the tail.

4. Install the Zipper

Add zipper tabs to reduce your zipper length to 8 inches. Align the zipper with the belly panel, sandwiching between outer and lining layers. Baste, then topstitch for a clean finish. Repeat this process for the opposite side, then unzip the zipper partway before moving to the next step.

5. Sew the Whale Body

Stitch the top panel to both side pieces, using careful alignment to maintain the curved seams. Repeat this process for the lining. Baste the fins and tail to the outer body using the marked placement lines. Use clips or washi tape to hold the pieces in place temporarily. Layer the belly unit with the outer body and stitch around the edge, keeping the lining free. Repeat for the lining unit but leave a small gap for turning. Turn the pouch right side out through the opening. Shape the edges and curves with the Hemostat and press flat.

6. Final Touches

Hand stitch the opening closed using a ladder stitch. Add a grommet to the top corner and embellish as desired.

Optional Embellishments

Add a personal touch with these simple ideas:

• Use ThermoWeb Sparkle Paste and a stencil to decorate the tail or fins before assembly
• Create a matching wrist strap using scraps and fusible fleece
• Add a name tag, charm, or patch using HeatnBond Lite and raw-edge appliqué 

Try the Pattern Club Free

ThermoWeb readers can enjoy one FREE month in the Sew A Story Pattern Club to access SVG cut files, printable templates, and more. Join HERE Use code: JUNECLUB

At Sew A Story...

We believe every handmade project has the power to inspire connection, spark imagination, and bring families closer together. We’re so glad you’re here. Let’s make something meaningful, together.