How to Sew Boxer Briefs

Use an old T-shirt and a sewing machine to make men's boxer briefs.

Boxer briefs combine the coverage of boxers with the security of briefs. Commercially manufactured boxer briefs are generally made of cotton with a Lycra blend. Boxer briefs sewn at home can be customized to fit you perfectly. You can use an old T-shirt and the materials used to manufacture boxer briefs. Wash all fabric before sewing. An experienced sewer can complete this project in one sitting.

Things You'll Need

• Old knit cotton T-shirt
• Lycra waistband
• Scissors
• Sewing machine
• Thread
• Straight pins

Instructions

1. Lay the T-shirt flat on a clean surface and cut a horizontal line with the scissors just underneath where the armpits meet the body of the shirt. This will create two portions. You will use the larger, bottom portion of the shirt to make the main part of the underwear and the top part to make the crotch.

2. Cut the crotch gusset out of the top portion of the T-shirt with the scissors, making sure to cut through both the front and back of the shirt to create two rectangular pieces. Make the crotch gusset according to the size needed. Crotch gussets for an average-size man should be 8 to 9 inches in length and about 2 inches wide. It is better to make it too big than too small, though, as it can be trimmed down later. Be sure the gusset doesn't contain any seams from the sleeves or the collar.

3. Subtract 2 to 3 inches from your waist size and cut the Lycra band to this measurement. Sew the two loose ends of the Lycra strip together to form the band.

4. Turn the bottom portion of the T-shirt inside out and align the cut edge of the shirt with the Lycra band so the seam of the band meets the edges of the T-shirt. Pin the T-shirt to the band. Sew the two pieces together all the way around the band. The T-shirt portion will be larger than the band, so pull and stretch the Lycra material to accommodate the size of the T-shirt as you sew.

5. Fold the bottom portion of the T-shirt in half vertically. Cut a 2-inch quarter-circle out of the bottom, folded corner. This will be on the side that does not have the band sewn onto it. The quarter-circle will allow the crotch piece to be attached and create the leg holes.You can adjust the quarter-circle's size, if needed.

6. Put the two rectangles cut for the crotch gusset together with their right sides facing each other. Sew together the two shorter edges of the rectangles, then turn them right-side out.

7. Place the crotch gusset horizontally along the bottom of the T-shirt where you cut the quarter-circle so each of the sewn shorter sides of the crotch reach the bottom of a leg hole. Pin the gusset so the right sides are facing each other, with the wrong side of each piece facing out.

8. Turn the pieces wrong-side out and sew each side of the crotch gusset to the bottom of the T-shirt so it fully covers the quarter-circle you cut out of the shirt. The arc of the crotch gusset will align with the arc of the quarter-circle and the leg holes will align with the edges of the gusset. Clip any excess threads.

References

• The Burkshires; Boys Boxer Briefs