DIY Quilt

Just my opinion but a down backpacking quilt is absolutely not a good learn-to-sew project. The materials are expensive (unless you already have down that you want to recycle) and difficult to work with. I've done a lot of sewing and made a lot of gear, including a synthetic quilt, tarptents, etc., but after making a baffled down vest a long time ago, I decided a baffled down quilt was something I really didn't need to conquer.

Sewing UL gear means sewing super-fine slippery fabrics. If you're a beginner, expect to spend extra time tacking (temporary hand-sewing seams to keep fabrics in place); it will be worth your time. Take the time to set up your sewing machine for the correct tension/pressure; again, worth your time.

Pay attention to the hints and instructions on handling down. The stuff gets *everywhere* and it's really easy to "lose" precious ounces into thin air, especially when you're dealing with the high-fill-count stuff. There are various strategies -- have one before you open up the bag!

Resist any temptation to get ambitious about a constructed/sewn footbox.

If your goal is to make the quilt as light as possible, learn about what makes a fabric down-proof. Not all fabrics are. I would not go to your local Joann Fabrics to buy fabric. Thru-hiker.com is a good resource for both instructions and materials. They offer a down quilt kit which is a good place to start in terms of a materials list. And in their "Projects" list, there are instructions for a down quilt; definitely worth a read before committing. Prices can be a little high here, but the quality of the information is solid.

I get most of my materials from Quest Outfitters, everything from fabric to down to cording, zippers, etc. They're super helpful on the phone, so you can call and ask about fabric weight, whether it's calendared (down-proof), etc. They sometimes have small quantities of very cool (proprietary) fabrics that aren't on their website.

Outdoor Wilderness Fabrics is generally more well-known, bigger selection of fabrics. There are also various cottage gear companies that also sell raw materials (like the lightest cuben fiber for baffles.)

FWIW, my biggest money-saver DIY projects are small things based on widely available fabrics, like silnylon, WBP wearables, high-performance fleece. Larger items, like quilts, tarps, etc., can save some money but I think the biggest advantage is in weight-savings since you can size them exactly to your specifications and the construction doesn't have to be as robust as commercially manufactured counterparts.

Btw, what is motivating you to make another quilt if you already have your Go-Lite?

Dang. No kidding.  Great stuff.  

You're correct, I don't really need one. Maybe it's the just idea of making one that intrigues me. And after you've described the process a little more maybe I'm thinking I'll stay away for now. Well that along with this comment.


Maybe I'll find something on a smaller scale to start with.