I
n the list of iconic fashion garments, there are a few classics that 
are included without fail: the little black dress, the crisp white shirt, 
the belted trench coat, and the classic French cardigan jacket. What 
they share is an uncomplicated elegance and a clever marriage of 
fabric, ft, and design. But in none of these garments is the partner-
ship more splendid than in the cardigan jacket. With the added 
element of sewing techniques that brilliantly bring the design to life, its 
no wonder the term classic so aptly applies.
Ive always been a devotee of haute couture sewing, starting way 
back when my grandmother was a client at New Yorks couture salon 
Chez Cez et Bez. When a wrist injury cut short my career as a classical 
pianist, I applied for a job almost on a lark at Chez Cez 
et Bez. To my amazement, I was hired to train with the 
most talented designers and seamstresses, and at the 
salon, I was able to poke around in boxes of fantastic 
garments from various couture houses. Packages from 
Chanel were my favoriteswhen I inspected the gar-
ments seams or oh-so-carefully peeked inside a lining, I 
was amazed by the fne, ingenious handiwork.
In the following pages, I will show you how to sew the 
four key features of a classic cardigan jacketquilted 
rows of stitches that anchor the soft boucl fashion 
fabric to a slinky lining; hand-fnished seams that pro-
vide hidden strength and support; a hard-working and 
decorative chain weight at the hem; and bold trim and 
buttons for design interest and stability. Tere really is 
nothing like a classic French cardigan jacket, and every 
woman deserves to have the simple style, luxury, and ut-
ter comfort of this unique garment in her wardrobe.   
Susan Khalje (SusanKhalje.com) is a couturier and cou-
ture sewing teacher, host of DIY.nets Sew Much More, and 
Treads newest contributing editor.
Luxury must remain almost invisible,       but it must be felt 
                                       Coco Chanel
       Inside  a
Designer  Jacket
Subtle quilting, hand- 
finished seams, a chain  
weight hem, and fine 
trims are hallmarks of  
this classic garment
BY   S US AN  K HAL J E   ( F R OM  I S S UE   #1 2 1 )
2  THREADS
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1
Quilt the fashion fabric 
   directly to the lining
Soft, drapey wool boucls are typical of a cardigan 
jacket. Theyre backed by a charmeuse or crepe 
de Chine lining and supported by machine quilting. 
The effect is soft, with just the right amount of 
underlying structure.
1. Fit a muslin, then use the muslin pieces as your 
pattern. When you are pleased with the fit, rip out 
all stitches and press the pieces flat. To help align the 
muslin pieces along the lengthwise and crosswise 
grain of your fabric, cut off the seam allowances, and 
draw grainlines that extend to the seamlines on each 
piece. Lay out your wool in a single layer, then carefully 
position your full set of muslin pattern pieces (left 
and right fronts, left and right sleeves, etc.) along the 
fabrics grains. Using a double length of contrast thread, 
baste around each muslin piece to clearly identify your 
seamlines and hemlines, then cut out with at least a 
two-inch seam allowance. 
c ont i nued
Luxury must remain almost invisible,       but it must be felt 
                                       Coco Chanel
Jacket 
provided by 
Chanel USA, 
from the Fall 
2005-2006 
collection.
THREADS   3
2. Layer the lining and fabric 
piece, then quilt vertical lines 
about one inch apart. Place 
the charmeuse wrong side up 
on a flat surface, then place 
the cut fabric pieces right side 
up on top, making sure the 
grainlines are perfectly aligned. 
Cut the charmeuse roughly in 
the same shape as each fabric 
piece (no need to be precise 
yet), then mark the quilting 
lines with pins spaced one inch 
apart. Machine-quilt along the 
pinned lines using a walking 
foot, on 3mm stitch length, and 
holding the fabric taut as you 
sew. Stitch all quilt lines in the 
same direction, and start and 
stop one inch from seamlines, 
and two inches from hemlines. 
To keep the lines straight, you 
may not be able to extend 
them all the way to the top of 
the jackets side panels.
3. Tie off the thread ends 
between the layers. As 
you quilt, dont back-tack at 
either end; this looks messy 
and can distort the fabrics. 
Instead, pull up each pair of 
threads between the wool and 
charmeuse layers and knot 
them securely with jewelers 
knot (tied around a pin at left). 
Clip the thread ends down  
to 
1
2 inch.
Hand-finish  
the lining seams
Hand-finished seams provide a cardigan 
jacket with hidden strength. Sewing by 
hand also allows better control of the 
slippery fabrics. I call this the woolly 
mammoth stagethe wide seam allow-
ances are frayed.
1. Machine-baste the pieces along the 
traced lines, but dont catch the lining. 
Pin the fabric pieces together along the 
hand-basted seamlines. Use a walking foot 
and a long stitch length (I used 5mm) to 
join the fabric pieces, and hold or pin the 
charmeuse out of the way as you stitch. 
Try on the garment to evaluate the fit, and 
when satisfied, stitch the seams for real. 
Remove any stray basting lines.
2. Press the seam allowances open, then 
trim. Using a sleeve board to isolate the 
seam, press the seam allowances open. Trim 
them down to about 
3
4 inch (leave as much 
as you can to strengthen the seamlines, but 
make sure the seam allowances will clear 
the nearest line of quilting). Press the seam 
allowances open again.
Quilt the fashion fabric continued
2
Extra-wide seam allowances are a must
The loosely woven boucl frays considerably during the 
construction process. Wide allowances also allow for any 
pulling up of the fabric during quilting. And because the 
armholes of cardigan jackets are typically high and tight, this 
extra fabric provides more opportunities for fit adjustments.
tip
3
Fell stitches secure all seams 
of the fluid lining fabric.
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3. Overlap the lining layers, using pins to 
transfer the seamline. Gently smooth one 
of the charmeuse seam allowances over 
the garment seamline (do not pull or tug 
it, though, and make sure the grain doesnt 
shift), then pin along the seamline as 
shown at right. Start and stop pinning one 
inch from seamlines and two inches from 
hemlines. Trim that seam allowance of the 
charmeuse down to about 
3
4 inch. Overlap 
the other charmeuse seam allowance, and 
lightly press over the pins. The pin heads 
create indentations in the charmeuse, 
indicating the seamline. Trim this seam 
allowance as well, 
3
4 inch from indentations.
4. Fold the upper layer of lining in place, 
then secure with fell stitches. Fold under 
the charmeuse along the indentation and 
pin in place. Gently press to create a sharp 
foldline, which will be easier to sew. Lift  
the garment off the sleeve board and 
secure with a fell stitch, catching the  
wool underneath.
5. Set the sleeve by hand and finish the 
neck and center front. Place the garment 
on a dressform and pin the sleeve in place. 
The sleeves are then easiest to sew in by 
handthe all-important grainlines can be 
perfectly positioned and controlled, and 
any extra fullness in the cap area is easy to 
distribute. Staystitch the fashion fabrics 
neckline and center front, then trim, clip, 
and turn the seam allowance to the inside. 
Trim, clip, and turn the lining (cheating 
the lining about 
1
8 inch to the inside), then 
secure it to the fashion fabric with small, 
tight fell stitches.
4
5
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Apply a special  
trim and buttons
Use a single purchased trim, combine or 
layer trims and ribbons, or fringe your 
own trim for a unique look. Youll need 
about five yards of trim to embellish all 
of the jacket edges, sleeve vents, and 
pocket edges.
1. Create fringed trim from your fashion 
fabric. Cut two strips of fabric about two 
inches wide, then pull threads to the 
desired fringe width. The fabric may have 
different fibers in the lengthwise and 
crosswise grains, so experiment to see 
which gives the most interesting fringe. 
Layer the strips together, then sew a ribbon 
or trim down the center. 
2. Pin the trim in place, folding under 
loose ends and manipulating it around 
corners. Using a single length of thread in 
a color that blends in with the trim, firmly 
secure both edges of the trim with tiny 
backstitches.
1. Hem the fashion fabric with  
  a very loose catchstitch. Pin  
  the lining out of the way, then  
  press up the fashion fabric  
  along the basted hemline; trim  
  the hem allowance so it rests  
  along the base of the quilting  
  lines. Hold in place with a  
  loose catchstitch.
2. Secure the lining with a    
  catchstitch. To make turning  
  easier, first baste the linings  
  vertical seams closed. Then  
  finger-press the lining in place, 
  3
8 inch from the jacket  
  hemline. Finish the vertical  
  seams and the lower edge of  
  the lining with fell stitches.
3. Hand-sew the chain right 
below the lining. Pin the 
chain in placeit should not 
be too tight (this will gather 
up the fabric), or too loose (an 
unwanted flare will result). 
Strengthen a double thread 
with beeswax, and secure the 
top and bottom of each link 
using small backstitches.
Insert a chain weight at the hem
The weight of bold buttons on a classic French cardigan jacket pulls the 
jacket forward. A chain at the hem served as a counterbalance; it also en-
couraged the jackets back to hang close to the body. Its really only needed 
in the back, but for style, run it along the entire hem. 
1
2
3
Chain weight should match fabric weight
 There are a variety of chain weights to choose from; 
youll need to hold a few different ones in your hand 
to get a feel for what will work best in your jacket. As a 
general rule, use a larger, heavier chain with a heavier 
wool, and a smaller, lighter one with lighter-weight 
wools. Youll need enough chain to circle the hem of 
your jacket (3 to 4 feet usually does the job).
tip
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Trim a pocket before you attach it
Fold and firmly press the fabric into your 
desired shape, then add the trim to the top 
edge. Fell-stitch a matching lining in place, and 
sew the pockets on by hand with beeswax-
coated double thread and a firm fell stitch.
tip
START WITH THE RIGHT PATTERN 
A classic cardigan jacket is gently shaped and usually 
collarless. Look for a pattern with princess seams that 
extend from the shoulder; the quilting will be more ef-
fective. The signature three-piece sleeve allows for better 
vent placement, as well as fine-tuning the fit, but a two-
piece sleeve will also work. Here are a few patterns that 
give you a designer cardigan style.
  Burda 8414  McCalls 4311  Simplicity 4971 
  Butterick 4028  Simplicity 4954  Vogue 7975
(authors 
own pattern)
THREADS   7 www. t hr eadsmagazi ne. com
LINTON TWEEDS LTD
(produces much of  
Chanels fabric)
Shaddon Mills
Carlisle, Cumbria CA2 5TZ 
England
011-44-1228-512062
LintonTweeds.co.uk
MENDEL GOLDBERG FABRICS
(Chanel-type boucls and 
matching charmeuse linings)
72 Hester Street
New York, NY 10018
212-925-9110
Email them at
MendelGoldbergNY@aol. com
SOURCES
History of a Timeless Garment
M&J TRIMMING
( fancy trims and buttons)
1008 and 1000 Sixth Avenue
New York, NY 10018
212-391-6200
MJTrim.com
TINSEL TRADING COMPANY
( fancy trims and buttons)
47 West 38th Street
New York, NY 10018
212-730-1030
TinselTrading.com
TOHO SHOJI 
(NEW YORK) INC.
(gold and silver chains,
sold by the foot)
990 Sixth Avenue
New York, NY 10018
212-868-7465
TohoShojiNY.com
Its one thing to be a designer 
who reflects the mood of the 
times; its quite another to be 
a visionary.  
Coco Chanel (1883-1971), who 
early on encouraged women 
to dress with ease, confidence, 
and elegance, once stated, I 
want to be a part of what is to 
come.  And with faultless taste, 
audacity, and determination, she 
was. Chanels garments were 
astoundingly different from the 
tightly corseted garments of 
the not-so-distant Belle Epoque, 
and they suited a generation of 
women who were entering the 
workforce, driving motorcars, 
and participating in sports.
The design provenance of the 
now-famous Chanel suit is vari-
ously ascribed to Tyrolean jack-
ets, military dress, riding clothes 
of the British aristocracy, even 
bellhops uniforms. Regardless, 
its an eminently wearable bal-
ance of a basic jacket/cardigan 
and brilliant ornamentation. 
Most of all, it supports Chanels 
claim, Elegance in clothes 
means freedom to move freely.
Jacket 
provided by 
Chanel USA, 
from the Fall 
2005-2006 
collection.
Luxury is the coat a woman 
   throws on the reverse on a 
chair  and the inside is more 
               precious than the outside. 
        Coco Chanel
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