Customer Project: Mem10 Karo Step Top Quilts

by Jim

I did some in depth research on TQ designs and easy of stuffing won out over easy of sewing .
My karo Step design is a 10" box with 6" baffles.  I did a polygon foot box over a circle for additional foot space  

Customer Project: Mem10 Karo Step Top Quilts
Customer Project: Mem10 Karo Step Top Quilts
Customer Project: Mem10 Karo Step Top Quilts
Customer Project: Mem10 Karo Step Top Quilts
Customer Project: Mem10 Karo Step Top Quilts
Customer Project: Mem10 Karo Step Top Quilts
Customer Project: Mem10 Karo Step Top Quilts
Customer Project: Mem10 Karo Step Top Quilts

Materials

3 Yr - 0.66 oz Membrane 10 Taffeta outer and inner shells 
1-   2.5 inch Noseeum baffle 
12oz 950fp down 
Related Products:

How do I make it?

        Down Requirements
Length | 76
 Width  | 58
 Loft | 2
 Minus Taper (LxW) | 20
Total Cubic Inches | 8,632
 Down fp | 950
 OZ needed  | 9.0863
 Overstuff %  | 20.00%
 Total OZ of Down needed to order | 10.9036


1) lay out material and cut to length , and cut in tapers.  Use tape and heavy weights to hold down and prevent fabric from moving

2) Lay out Karo step baffles , find middle length and width divide length by 4 and width by 5 rough estimate .

3) do both outer and inner shell the same dimensions and karo step

 4) fold over a 1/2 inch and stitch the outer hem

5) attach garment loops to inside (shine Side up )of shell line up with baffle line.  Attach foot box loop  to outside of fabric (dull Side)  and fold back, this will prevent feeling it while sleeping
 
  6) install eyelets for draw string shock cord (reinforce for strength)

  7) tape baffles in place on one of the shells , sew in place attach to inside shell check often to correct any mistakes quickly double stitch all connection seams.  I numbered each taped baffles and numbered each baffle location on the other shell to ensure my baffles lined up

8) sew in triangle reinforcement for sewn foot box cut , fold and sew
 install it where taper starts between the two shells with triangle pointing down on one  side
 
  9) sew two shell together at the top , remember to sew in channel for shock cord  double stitch all sides , but leave a hole for the down
 
 10) triangle side and the bottom sew together  after you should have 3 sides sewn together top, side and bottom
 
 11) turn  bag inside out and sew the foot box.  Place triangle side between the two shells and sew together . After stitching together fold over and flat stitch it to make a smooth seam
 
FOOT BOX
 12) measure the opening on the end 
  13) cut it , hem it and add baffles and stitch it , re-measure before stuffing 
  
  14) with shell turned inside out sew box on to the two shells 
 
 15) compress down and fill bag ( need a place with no draft or air movement ) 

16) sew close opening 

 shake the bag or put in dryer with tennis balls to spread down