Customer Project: Utility Bedroll

by Heath Jackson

• OVERVIEW
• HOW DO I MAKE IT
• MATERIALS

• After seeing several cool bedrolls online, I set out to make a lightweight, yet extremely durable bedroll. Not only would I use this roll under a sleeping bag, under a lightweight bivy, or quick naps on a hike, but I would also use this at kids football games to sit on, as a moisture barrier between my seats and a kid's rear after a fishing trip, and at the park for a picnic. So, light was important, but I also wanted extreme durability.
  
  I decided on a 1000D Cordura (11oz/yard2) base and a 2.2 Hex70 XL top. The Cordura would last forever and likely never tear. The Hex 70, while also durable, looks amazing and is very soft to the touch. I wouldn't change a thing about the materials that I chose. I am considering making an extremely lightweight roll at some point, but if I need lightweight, I would just leave the bedroll at home.

  
  

  On the thread, I used Gutermann Mara 70 in Vader Blue. This was a mistake, as I meant to use the Olive Yellow color. The blue does not look great against the black. I made a wallet using the black Cordura with Olive Yellow thread and it looks amazing. I suggest going that route.

  
  

  The final weight came out at 1.9 lbs (30 oz.) and I couldn't be happier. Everyone that sees it wants to buy it from me. My eight year old begged me to let him sleep on it the first night because it was so comfy! I got my money's worth the next day as my soaking wet 13 year old sat on it in my car for 30 minutes after our successful fishing trip. The seats were completely dry when we arrived.

  
  

  The dimensions are 36" by 84", but I cut the material an inch long on all sides. You could leave the Hex 70 at 36" by 84", but I wanted to reinforce the seams as much as possible.
• Steps:

  1. Cut out desired length and width of shell material allowing for desired allowances
  2. Cut out lining material at or shorter than shell material. I used seam allowances of 1 inch. If you choose that, then reduce the size of your lining by 1/2 inch on all sides.
  3. Cut out installation at same length as lining (I did not use installation.)
  4. Place wrong side against wrong side and fold your seams up. Pin or clip in place (I wouldn't use pins even in the seam allowances.)
  5. Sew 1/8 inch inside of seam allowance all the way around. As I mention below, I overlapped the corners. I suggest that you miter, unless you need the strength for buckles or tie outs.

  Best Practices: 

  1. Decide if you want to use any tie outs or buckles before getting started. I decided not to use any because of additional weight and I will use a stuff sack. If you want tie outs or buckles, sew them into the seam between Hex70 and Cordura. 
  2. Determine your comfort level and desire to quilt. While quilting the top looks nice and likely adds durability, I decided not to do it. I like that the Hex70 moves slightly with you and I didn't want to risk mistakes on the top due to my average sewing ability. I have only been doing this for a month. 
  3. If adding buckles for ease and strength, determine how you will want to fold the roll. I fold mine over twice and roll it into a ball (trash bag method.) You may want to go the way of the All Terrain Bedroll, which rolls all the way up and then folds end over end. That will determine where the buckles need to be added. 

  
  Lessons Learned: 

  1. Use your favorite seam finishing technique on the Hex70 before sewing to the Cordura. I did not and had to clean up some fraying from the Hex70 after I finished. 
  2. Miter the corners. I overlapped them to save time and to reinforce the strength, but it wasn't worth it. As it turns out, with not using any hardware, I didn't need the additional strength, and the mitering would have improved the look. 
  3. Make sure that you do what I should have done and make sure that you have the right color thread in your machine before getting started.

• Required Materials:

  1. Thread - Gutermann Mara 70 in Vader Blue
  2. Shell -1000D Cordura (11oz/yard2)
  3. Lining - 2.2 Hex70 XL

  Related Products:

  • 1000D Cordura®
  • 2.2 oz HEX70 XL
  • Gutermann MARA 70 Thread