I got to work on a little project for my husband this past week. Every year I make or buy new pajamas for my kiddos to open on Christmas Eve and this year my husband made a comment that he would like some, too. So I pulled out my trusty machine and got to work!
Pajama pants are super simple to make! I didn't even use a pattern, just laid some pants in his size down on the fabric and cut. If you try this at home, just make sure you fold the pants in half along the waist with the inseams on one side and the side seams along the other.
Your fabric comes folded. Just fold it again the long way so the fold runs the longest way (in school we called it "hot dog" style not "hamburger") and lay the side seam of your folded pants along the fold. There will be 4 layers of fabric to cut plus the old pants on top.
Now be brave and cut about half an inch away from the edge of the pants, along the inseam. Cut 1 inch away from the bottom cuff and 1 1/2 inches from the waist edge at the top. This will allow for a casing for the elastic and a new cuff at the bottom.
Now for the fun part! Take the fabric pieces you just cut and separate them. With one in hand, fold it in so that the right side of the fabric touches. Pin and sew along the inseam, or shorter edge, with a 1/2 inch seam allowance. Now do the other side.
To put the two legs together, flip one out so that the right side is out and put it inside the other leg, right sides of fabric together, matching up the waist and inseams. Pin and sew along that curvy part that is like a "U", starting at the waist on one side, down and up to the waist on the other side. Sew with a 1/2 inch seam allowance.
Pull that leg out of the other and, voila! You have pants! To finish, serge all seams and around the bottoms of the legs and the waistline. Or, if you don't have a serger, fold down the waist 1/4 inch to the inside and press. Fold again, 1 1/4 inch and press (if you used a serger, continue with this step). This is your casing for the elastic. Starting at the back, center, sew on the inside along the fold, backstitching as you start and stop, stopping a couple inches from where you started.
Measure waist. Cut elastic 1/2 inch longer than what you measured. Put a safety pin on the end and thread it through the casing you just made at the top of the pants, making sure not to lose the other end inside the casing (not that I've ever done that before, wink wink!)
Make sure the elastic is straight, try it on, then overlap the ends of the elastic 1/2 inch and zig zag stitch them together, going over it a couple times. Then straight stitch the opening in the casing closed. You may need to stretch out the elastic a bit to get it just right.
To finish, fold the cuffs 1/4 inch to the inside and press. Fold again, 3/4 inch this time, and hem around the cuff, close to the fold. Repeat for the 2nd cuff and you're done! You made some pants without the help of a pattern, good job!
And here's how mine turned out. They're even doing a happy dance, too!