I made a ten new pillow covers to go with our new furniture. To help me remember, here's what I did.
For a 20x20" pillow form:
1.) Cut one piece of fabric 20x44". 44" is typical for the width of fabric, so this is partially where this number comes from. It also ends up being a good amount for the envelope ends to overlap. I ended up using decorator weight fabric which is wider, so I cut my fabric down to size.
2.) Iron the edges of the 20-inch sides. I first ironed over the edges at 3/8" and then a second time at 3/4" (6/8").
3.) Sew a seam to keep the folded edges in place. I used a 5/8" seam allowance.
4.) Put the piece of fabric on a table with the right side up. You'll sew the envelope inside out and then turn it right side out when it's done.
5.) Fold one 20-inch end down 10". Fold the other 20-inch end toward that fold so that there is a distance of 19" from one fold to the other. Even though I used a 20x20" pillow form, it's better to sew them a little smaller so the pillow form fills up the pillow cover. Pin along both raw sides.
6.) Sew the side seams using a 1/2" seam allowance. I usually pull out the pins right before the needle reaches them.
7.) Cut notches on the four corners to help minimize bulkiness. I also sewed along the raw edges with a zig-zag stitch to help prevent fraying if I end up washing the covers. With my two monkeys, that's pretty likely. You could also serge the raw edges.
7.) Turn right side out and insert the pillow form. TA DA!!!
Adapted from this tutorial:
http://littlegreennotebook.blogspot.com/2012/08/easy-envelope-pillows.html
