Blog cover image with back of two pillow covers, both in envelope pillow covers; one is gold the other navy blue with white stars. Title is Envelope Pillow Cover Tutorial, Learn to make your own pillow covers step by step.

Envelope Pillow Cover Tutorial

As I was creating my bi-monthly quilt block for my Quilty Club members I figured I should probably give an optional pillow finish, but how to do that without necessarily including it in every pattern—I’m trying to keep the patterns simple enough to be one front and back page (we’ll see how that goes as I have a tendency to have “complicated” patterns in my head 😆). Either way I want to keep the pattern short(ish 😁), so having the pillow cover tutorial here seemed the best option.

** This pillow cover tutorial will be for an 18” square pillow cover. For bigger or smaller covers the directions will remain the same, but the sizes of cuts will vary.

As pillows come in whole sizes, we need to make sure the block size we are using is ½” larger than the pillow. For this we are making an 18” square pillow, so the block needs to be 18½” square, this allows for seams or binding.

I will have both sets of directions—a turned-out pillow (navy) and a pillow with binding (white). I’ll make sure to let you know where they vary.

Christmas Star Pillow turned-out envelope pillow cover; gold star with navy background Christmas Star Pillow envelope pillow cover with binding; white background with gold star and binding

 

Oh! A quick note, I don’t like having the envelope seam in the middle of my pillow; I’m always afraid I’m going to rip seams as I’m stuffing the pillow 😆, so my directions will have the envelope part higher (at about 1/3 from the top) on the pillow instead of in the middle.
Envelope Pillow Cover back. Overlap is split 1/3 from top. Fabric is white stars on navy background

 

Let’s get started…

For our 18” pillow we’ll need 18½” wide pieces of fabric, so if you’re purchasing new you’ll need to purchase 5/8 yard of fabric.
Pins
Rotary cutter
Hemming tool

If you’re turning-out your pillow you’ll need
point turner of some kind
thread to match pillow cover
fabric scissors

If you’re binding your pillow you’ll need
thread to match your binding
2 - 2½”x WOF strips for binding (I’m not doing a binding tutorial here, but I’ll get you to that point).

Items to make envelope pillow cover, fabric, rotary cutter, hemming tool, pins, matching thread, etc

Cut your fabric to 18 ½” wide, if it’s not already.

Subcut it to
     1 – 8 x 18½” strip
     1 – 14 x 18½” strip

Two cut strips of fabric, one at 6" and one at 14"

I know you’re probably thinking, Tracy, why does the 6” + 14” not equal 18”??? Well, we want an overlap to cover our pillow insert 😃. In this case our 18” finished pillow will have approximately a 2” overlap; for smaller pillows you can decrease the overlap to 1”, and for larger pillows you can even increase it, but I don’t imagine you’d need anything more than a 3” overlap unless it’s a monster sized pillow or your pillow insert is super fluffy.

Gold fabric with a corner turned down to show the overlap

Press fabric ½” wide along 18½” side, wrong sides together (WST).
Then open and fold small edge in toward pressed edge, again WST.
Fold the pressed edge back in and press, this will give you a hem for the envelope edge.
Repeat this with the other strip of fabric.

Fabric being pressed at a 1/2" Fabric being pressed for a hem Fabric being pressed for a 1/4" hem


Topstitch, with a straight or fancy stitch, the hem to secure it.

Hemmed fabric that's been topstitched

 

This is where you’ll start seeing the separation of turned-out versus bound pillow…

Christmas Star Pillow by Essentially Loved Quilts Christmas Star Pillow envelope pillow cover with binding; white background with gold star and binding

 

For the Bound Pillow

Lay your quilted pillow block right side down.
Lay your 14” strip on top with right side up. The hem should be toward the top with the bottom edge of the fabric lined up with the bottom edge of the pillow block.

Quilted Block face down with corner being turned up to see front Pillow cover face down with back laid on top


Lay the 8” strip on top with right side up. The hem should be toward the middle with the top edge of the fabric lined up with the top edge of the pillow block.

Pillow cover backing pieces laid out


Skip down to the heart 💜. 

For the Turned-Out Pillow
Lay your quilted pillow block right side up.
Lay your 8” strip on top with right side down. The hem should be toward the middle with the top edge of the fabric lined up with the top edge of the pillow block.

Christmas Star pillow block face up with top envelope fabric covering it, right sides together


Lay your 14” strip on top with right side down. The hem should be toward the top with the bottom edge of the fabric lined up with the bottom edge of the pillow block.

Envelope backing covering pillow face, right sides together. View of inside of envelope pillow before backing sewn on

 

 

💜 Pin. I double pin where the hemmed seams are for a couple reasons, 1) so I know where there will be more bulk going under my foot and needle and 2) so I extra secure the seam (I’m rough on things, remember 😆).

Double pinned edges of envelope pillow where seams overlap 
Pinned edges of envelope pillow cover before sewing Pinned edges of envelope pillow cover before sewing

 

Sew a ¼” seam all around your pillow on the quilted-pillow-block side. I highly suggest using a walking foot for even feeding—you have lots of layers under that foot, and if you’d like some extra reinforcement for the “envelope overlap” feel free to sew over it an extra time.
I go forward over both double sets of pins on one side, then go backward over them, then continue forward to finish the pillow seam.

Starting sewing 1/4" seam on envelope pillow cover Reinforcing my 1/4" seam on envelope pillow cover where the two envelope fabrics overlap.


Do a quick quality control check by checking the pillow backing to make sure you caught all the fabric in your seam.

Checking my finished 1/4" seam after sewing around the pillow cover. Quality control check to make sure the backing was all caught in 1/4" seam


Trim any excess backing from the block, leaving ¼” seam allowance.

Trimming excess backing fabric from pillow cover, leaving 1/4" seam allowance Trimming excess backing fabric from pillow cover, leaving 1/4" seam allowance


For the Bound Pillow

This almost completes your envelope pillow cover, it’s time to bind it and you’ll have a beautiful pillow cover to adorn your home or gift to someone special.
Skip on down to the heart 🩵. 

Christmas Star Pillow Cover finished, awaiting binding


For the Turned-Out Pillow

After you trimmed the excess backing you’ll need to trim your corners. Most recommendations say at a 45°angle off the corners. I prefer to trim something closer to a 30 or 60° angle on each side of the corner, so there is less bulk.
Important: Do NOT cut across that seam! Or you’ll be sewing that corner over again
I also suggest not cutting too closely or you may poke through the corner when you’re turning it.

Trimming the corners on the turned-out version of the envelope pillow cover


Turn the pillow right side out being careful when poking out your corners. I love my OESD point turner for this as it has a bigger end I use for most of the poking and a smaller end I use to get that last little corner out, but Be CAREFUL, I’ve still poked through the corner before 🤦🏻‍♀️️.

Turning out the pillow cover using OESD point turner Turned out pillow cover awaiting pressing

 

Now press the edges of the pillow cover to really make the shape more defined.

Pressing the edges of the pillow cover after turning out. Finished Christmas Star Pillow Cover using turned out version

 



🩵 Last, but definitely not least, stuff your 18” pillow insert in! 🥳

Finished and stuffed Christmas Star block envelope Pillow Cover Christmas Star Pillow envelope pillow cover with binding; white background with gold star and binding


Now go and make some beautiful blocks to turn into pillows! Show off your new skill, we definitely want to see it; I know I would, so please tag me in your finished creations! 

Warmth & Love,
💜 Tracy

 

PS. Turning "orphan" or practice blocks into pillows is a great way to make use of them! 😃

PPS. If you'd like more sewing tutorials you might like these:

Bowl Cozy Tutorial

Casserole Hot Pad & Trivet Tutorial

 

 

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