Sewing Cafe

Patterns, Tutorials and Works in Progress from the Sewing Studio of Lynne Williams

Saturday, September 3, 2011

Wonder Boy Trunk Tutorial

Voila' Trunks fit for your helpful side kick. 

Now lets learn the finer points of sewing them up.

Due to Chucks mighty hunting powers, we are fortunate enough to have some original cotton spring weave fabric which has been dyed to match the Pantone color in the
The original fabric was loomed on a 10" tube which eliminates all vertical seaming.  Pretty neat:)
The trunk pattern has been drafted though for current standard widths, and you will want to follow the pattern directions for the layout. The pattern sits on the tubular yardage along one fold line and along the center back stitch line, thereby eliminating the unnecessary seam allowance.

The spring weave is quite thick when not stretched to its full potential and so I used pins  to hold the tissue in place and then cut with scissors.
 My rotary cutter just couldn't accommodate the bulk.
Mark your eyelet hole placement using Tailors tacks, or a light colored chalk pencil.

Once you have marked it remove the tissue carefully so the thread remains on your fabric.  Separate the fabric layers and cut the thread in between leaving thread marks on both layers.

My Bernina provides a nice little stitched eyelet hole.  Its #13 under the buttonhole stitches and uses the #1 foot. 
 Always stitch a sample on your fabric to check for tension issues. 
If you do have tension issues consult the manual for your machine.

I have stitched my sample in a contrast color just so you can see what the stitch looks like.  When I use matching thread it practically disappears.
Mine looks great, one of the things I like about my Bernina, rarely need to make tension adjustments:)

Leave thread tails when beginning and ending your stitch.
Pull tails to back and tie in a knot with the tails from that side.

Using a hole punch create a hole in the center of the stitching.

The original costume used a zig zag stitch to finish the seams.  So let's talk a bit about how to properly use your zig zag stitch for this purpose.

You don't want your zig zag to curl the cut edge of your seam, so proper width and stitch placement is important to keep that from happening. 
I can use the default the settings on my zig zag stitch which = 1.5m length and 3m width.

Release the tension between your foot and feed dogs to prevent undue stretching.  Zig zag with the cut edge running along the inside edge of your foot, so that when the needle jumps over to the far right position it stitches just off of your fabric.  This keeps the cut edge from curling under and creating a bulky rolled edge.

A note about the crotch seam.

You will notice when you place your front crotch seam to the back crotch seam that the back is longer.

 Pin the seam along both ends and then stretch until even and pin in the center.  This extra length in the back allows for a more comfortable seat coverage across the tush

Your stitched, zig zagged and edge stitch crotch seam.

Press your waistband and leg opening to the wrong side along the fold line indicated on the pattern.
Straight stitch leg casing 3/8" from fold, stretching a tad as you sew to insure the stitching will accommodate your upper leg circumference.
Straight stitch waist casing 7/8" from fold.

Run 1/4" elastic through the leg casing.  Over lap short ends and stitch across to secure.  Finish sewing casing.

These tiny trunks will actually stretch to fit a small male!

Run your shoelace through the waist casing and you are done.  You now own a pair of authentic and accurate side kick trunks. 

Now, to the Bat Cave...


  1. Hi, Lynne! I am delighted to meet you, I peeked in your blog and you have wonderful things, I think you never know enough and always learn more from others who are kind enough to show knowledge as you. I am very grateful to you for this.

  2. Lynne, thanks ever so much for the level of effort and detail that has not only gone into the patterns them selves but equally into these amazingly specific tutorials.

  3. Hi! Very clever superhero pants! Thanks for stopping by my blog...I'm appreciate your comments! Glad to "meet" you!

  4. Love this! I was behind someone at the SuperAmerica who was in a superhero suit, and I said "excuse me, but your costume actually seems well-made, where did you get it?" and he was a delivery guy for Galactic Pizza. The superhero costumes are their uniform. It's nice to see people putting some value into their dress-up clothes after all...

  5. Thanks for all the kind comments, its so fun and rewarding to meet new people ,share my love for sewing and learn from others as well.

  6. I just purchased this pattern. But I can't find tubular Spring Weave anywhere! Have any suggestions on where I can buy it?


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