How to Sew Color Guard Flags
Color guard squads often sew their own flags for a custom design and to save money. Designs can range from simple patterns with straight seams to more advanced ones with curves, but the same basic steps apply to any flag assembly. Keep the diagram of the finished design handy as you sew, and you might want to number the pieces, especially if there are a lot of them or if any are of similar size or shape.
Things You'll Need
- Iron and ironing board
- Polyester China silk fabric (yardage and color will vary with the design of the flag)
- Fabric shears or rotary cutter
- Diagram of what the finished flag will look like
- Straight pins
- Sewing machine
- Monofilament thread
- Adhesive-backed Velcro hook and loop strips (optional)
- Fray Check (available at fabric stores and craft stores)
Instructions
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1
Iron any creases out of the material, then lay it on a protected work surface and pin the pattern pieces in place. Cut the pieces from the material. Repeat for other colors and patterns.
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Refer to the diagram of what the finished flag will look like and pin two adjacent pieces together. Set the sewing machine for a straight stitch, then sew the pieces together with a half-inch (1.3 cm) seam allowance. Use a zig-zag stitch to tack down the raw edges of the seam allowance.
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Again referring to the finished-flag diagram, pin the next piece to the appropriate edge of the two pieces you just joined, then seam it in the same way (straight stitch first, then zig-zag to tack the edges down). Keep pinning and seaming until all the pieces are joined.
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Make the hem around the edge of the flag. Fold up and iron a half-inch (1.3 cm) width of fabric all around the outside of the flag. Repeat the folding and ironing to conceal the raw edges. Set the machine for a straight stitch and sew the hem down.
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Make the sleeve. There are two ways to do this, depending on your flag's design.
For a sleeve made from a separate pattern piece, first hem the edges of that piece. If you're using Velcro, sew the loop strips into the inner top and inner bottom of the sleeve (the hook strips will be mounted on the flag pole). Pin the sleeve to the appropriate edge of the flag, and seam it to the flag with a straight seam. Then make another straight seam about a quarter-inch (0.6 cm) away from the first seam (the double seam adds strength).
For a sleeve made from folding the existing fabric over, first sew in the Velcro loop strips (if you are using them), then lay out the flag so that the hemmed edge for the sleeve is on your left. Fold over and pin that edge to the place that the flag pattern calls for (usually about 2.5 inches in). Sew it, twice, with a straight stitch for strength.
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Cut, very close to the fabric, any monofilament threads that may have been left at the start or end of any seam. Then apply Fray Check to the entire length of every seam.
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Tips & Warnings
If you're sewing more than one flag, create one flag first, then have someone test-spin it before you cut pieces for and assemble the rest of the flags. That way, if any adjustments are needed, it's easier to make them.
You will probably need more than one bottle of Fray Check, especially if your flag design has a lot of seams. The standard size bottle is 3/4 fl oz (22.5 ml), which goes fast when you're covering long lines of stitches.
Polyester China silk is generally less expensive from online marching band suppliers, like the companies listed in the Resources, but you can get monofilament thread at a good price from any fabric or craft store.
Monofilament thread (also called fishing line) is the best choice for flag seams because of its strength--and, since it's clear, you don't have to worry about matching the color to the fabric.
Use caution when working with an iron, shears, rotary cutters, pins and sewing machine needles. Supervise youngsters who are helping to sew the flags.
