Yoshi Lunch Box

Yoshi is super excited to help my husband take his food on the go! I made some process improvements for this lunch box, but used the same dimensions as the one I made a little while ago for myself. Check out the pictures (click to enlarge) and scroll down for details!


Quilting cotton
Duck Cloth (or denim)
Insul-Bright Batting
Ironing Board cover fabric (lining)
Sport Nylon (bottom)
22″ Zipper
1″ Nylon Webbing (handle)

Cut List

Duck Cloth & Lining: 9.5″ x 20.5″ (top, back, bottom); 7.5″ x 22.5″ (sides and front)
TIP: cut slightly larger and trim to these sizes after quilting.
*Sport Nylon (bottom): 7.25″ x 9.5″
Batting: 6.5″ x 21.25″ (sides/front); 8.25″ x 19.25″ (top, back, bottom)
*Back  and Top: 9.75″ x 9.5″ (back piece extends to top); 4.25″ x 9.5″ (the rest of the top flap)
*Front: 9″ x 7.5″ (W x H)
*Sides: 7.25″ x 7.5″ (W x H)
* includes 1/4″ seam allowance for piecing, and 1/2″ seam allowance for assembly

The Process

Part 1: Design, embellish, trim to size

1. Plan designs, piece the background if needed, and embroider.

2. For the most accurate box, piece each of the panels first then sandwich, baste and quilt.

3. Trim panels and cut lining.

4. Mark seam allowances and center lines (important to help line things up later!) on all the pieces (panels, lining and zipper).

Part 2: Assemble

5. Stitch zipper to panels and lining (center zipper appropriately) starting with the front/side panel. (Note: align with the edge of the panels, and stitch as close to the zipper as possible. It won’t quite be 1/2″, but that’s ok.) Topstitch. For the top flap, it helped to baste with stitching first, then stitch again as close to the zipper as possible.

6. Start with center bottom of quilted panel. Center using markings and pin in place. Stitch bottom seam, stopping exactly at the corner of the seam allowances. Notch fabric to allow corner turn of fabric. Pin. Stitch bottom side seams. Pin the back sides and stitch.

7. Turn right side out, pin handle in place. Stitch.

8. Turn inside out again. Stitch lining together in similar order to the panels (leave hole in front bottom lining for turning – make sure the corners are stitched, but leave most of that seam open).

9. Hand stitch any spots where machine stitching wasn’t feasible (i.e., near the zipper tabs).

10. Turn right side out. Poke out the corners by reaching through the hole in the lining. Check for quality, and if it looks good, stitch the hole in lining closed.

11. Done!

Settings and Other Notes

Thread: Aurifil 50 wt cotton; Aurifil mono-filament clear

Needle: Microtex 60 (Inspira) – forgot to switch after quilting the clear, but it worked great even with the heavy fabric!

Quilting: 2.5mm stitch length, 0.6 tension for the clear thread in top, otherwise 4.2 tension; walking foot or clear echo foot for free-motion floating. I didn’t use the embroidery quilt block design due to time constraints…this time.

Seams: 2.0mm stitch length, 4.6 tension; B-foot

Zipper: 2.0mm stitch length; 4.6 tension, zipper foot

Webbing: 4-way stitches, S-foot

Marking: Frixion Pen (then realized that it might become visible when the lunchbox is cold!), invisible pen



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