Replacing a Jacket Zipper the Easy Way

Zipper missing a pin...

My other half is extremely hard on zippers.

Doesn't matter what sort of zipper — he eventually succeeds in mangling them in some way.

For zippers that lead into pockets on a jacket or a pair of shorts, I don't generally try to repair them. For the ones on his current "man purse," I've done my best to preserve them in working order for the time being, but then, I made him a whole new sling bag that's still waiting in the wings.

Prior to a camping trip back in May, he showed me an old system jacket and asked if I could do something about the front zipper.

Not only was the pin missing at the end, the zipper tape that it was attached to was frayed beyond repair, meaning that a so-called pin repair kit would likely be a waste of money. (They exist, in case you're wondering; but I would surmise that the zipper would have to be in extremely good condition for that kind of fix to be worthwhile.)

---

---

For my part, I had recently seen some YouTube videos of zipper replacements that were quite reasonable to attempt. Plus — I actually had a suitable zipper in my possession. Eleven years ago, I received a thank you care package from a reader that has continued to give to me on a regular basis. Among the sewing treasures I received were three separating zippers, one of which was the perfect shade of blue to match this jacket.

Imagine having a proper size and colour zipper in your stash!

In the above photo, the new zipper is laid out down the middle of the jacket... doesn't it look like it was meant to be? I mean, really, it's the exact length that was needed!

So how did I carry out this zipper replacement and how can it possibly be easy? Well, it doesn't involve using a seam ripper to remove the existing zipper, so just by eliminating that potentially challenging step – because sometimes the existing zipper tape is trapped between snaps and fasteners that cannot be disturbed – you may find this particular repair technique a good one to keep in your toolbox.

Carefully snip off the zipper...

The work involves simply cutting off the existing zipper tape, trimming as close to the stitching as you can get (you'll end up leaving a sliver of the zipper tape on the garment). There should then be enough zipper facing remaining on the jacket to sew the new zipper directly onto it.

Another view of the cutting process...

This has to be done carefully and slowly, as you don't want to cut into the fabric of the coat accidentally. A sharp pair of detailing scissors is a must.

Old zipper tape cut away from the jacket...

You will, of course, want to keep the zipper pull for reuse, but I'd recommend keeping the rest of it too. Trim back the zipper tape fully and keep just the narrow strip of teeth.

Zipper remnant pull...

Why? Because they can be cut into pieces and converted into zipper pulls, like I did here for my denim whale pencil case.

It's an idea I originally found in a book, where the author showed it on a wine bottle bag. It really is an example of how innovative we can be when we reuse the simplest things... with unexpectedly chic results.

---

Check out crafty classes at Creativebug! [affiliate link]

---

After the old zipper is cut away, pin the new one into place, making sure it butts up against the old seam under the zipper facing.

Pin (and sew) one side of new zipper...

Once the first side of the zipper has been sewn in, pin the other side to the other half of the jacket in the same way: close against the old seam, under the zipper facing. Separate the zipper and sew to secure.

Pin and sew the other half of the zipper...

Pin and pin well, to use my advice from a few years ago. You don't want the zipper to slip away from you when the strip of fabric that you're sewing onto may be fairly narrow.

This method of zipper replacement will result in more of the zipper tape being exposed than the original, but if your main objective is to get a coat or jacket in wearable condition again, you shouldn't care. In this case, with the colour of the zipper being such a fabulous match, I don't think it matters one iota. (Not to mention that this new zipper is also a two-way zip, offering more versatility for when hubby is sitting around a campfire and doesn't want the bottom edge of his jacket getting all bunched up.)

Ta da!

If you want to see this being done on a video, check out SewVeryEasy's channel on YouTube; enter how to replace a zipper in a jacket in the search field. (I've featured projects from that channel here in the past, like these fabric envelopes and this easy drawstring bag.)

Like I said above, you may want to file this technique away and keep it in mind for future consideration. I never expected to have to – or want to – change out a jacket zipper and yet, here I am. Glad it wasn't a hair-tearing experience!

Oh, and hubby said that this was the only jacket that he wore during his trip.

'Til next... 🇨🇦🍁