Soft shirts

About this time last year, when I sewed my first few pairs of fleece PJ pants for Littles, I had to figure out a way to make matching shirts. I had the idea to take plain t-shirts and embellish them appropriately, but I couldn't find reasonably priced long-sleeve t-shirts, and it didn't make sense to pair those nice warm fleece PJ pants with a short-sleeve shirt.

One night, I got the idea to make a long-sleeve shirt by sewing fleece "sleeves" onto a short sleeve shirt. The result...

Cute? Hideous? I'm still not entirely sure. But certainly, these shirts were fast and easy to make, cheap (I used leftover fleece scraps and standard Hanes boys underwear shirts, which I bought at Wal-mart for around $6 for a 5-pack), and very soft and warm!

I ended up making three shirts in this way last winter. We pulled them out again a few months ago as the weather started to cool off, and Littles has worn one of them just about every night since. A few nights ago, they were all in the wash, and Littles was very upset begging for a "soft shirt." We tried giving her some other shirts that are soft, but no, no. She wanted a cute/hideous fleece-sleeved "soft shirt."

So I got to work. And I took pictures this time to show how I put these together.

I start by taking a few key measurements. First, I need to know what length the sleeves must be. I do this by measuring an existing shirt -- or, in this case, one of Noob's onesies. It's about 7" from the shoulder seam to the cuff.

Since the sleeves of the short sleeve shirt will stay somewhat intact, I need to get some measurements from it, too. This is hard to see, but it's the sleeve of the short sleeve shirt. It's about 1.5" from shoulder seam to cuff, and the hem is about 0.5".

Now I can calculate how long my fleece sleeves have to be. They must be (total sleeve length) - (short sleeve shirt's shoulder seam to cuff length) + (short sleeve shirt's hem length * 2) + (desired hem length for fleece sleeve). Here, that was 7" - 1.5" + 0.5" *2 + 1" = 7.5"

As for how wide, the fleece sleeve needs to match the width of the short sleeve shirt's sleeve, so I need to measure that. Here, it's about 3.5". I'm going to use a 0.25" seam allowance, so that means that the fleece sleeve needs to be 3.5" * 2 + 0.5" = 7.5" wide.

So I cut two pieces of fleece with those dimensions. I folded each piece in half to create a tube.

I also prepared an embellishment. This shirt will go along with Noob's Dallas Cowboys PJ pants, so I cut a Cowboys helmet out of some fleece. (The same thing I used to embellish his sleep sack.) I've also used t-shirt transfers in the past, but they get all cracked and yucky-looking over time. Fleece is much more durable.

The shirt is a Gerber size 18 months shirt. Gerber stuff runs really small, so Noob has been wearing this since he was about 3 months old. I got it at a thrift store for about 50 cents. I've been looking and looking for plain white short-sleeve infant shirts like this in regular stores, but I haven't found any! Too bad. They are so versatile.

I started by sewing the helmet on to the front of the t-shirt. Then I started to work on the sleeves.

I folded the fleece in half, right sides together, and sewed up the open side. Fleece is much stretchier in one direction, so I made sure that the stretchiness was going across the width of the sleeve. That is, the open ends of the fleece tubes stretch more than the side I sewed up.

I turned the tube/sleeve right side out and the t-shirt inside out. I inserted the fleece into the t-shirt sleeve, right side to right side, and pinned it into place:

Then I sewed the sleeve into place. I think it looks best to sew right around the original seam line on the shirt sleeve. That way, you don't see the original hem line just above the new seam when you're done.

Here are both sleeves finished. You can see the navy blue thread that I used, right near the original seam line. On the bottom sleeve, I've also trimmed the seam allowance:

Then I hemmed the bottoms of the sleeves. You could actually leave the raw edges if you wanted; fleece doesn't fray.

All done!

Here's how it looks! (Please ignore the strawberry yogurt all over the front. I should have done the photo session before breakfast.)

(Yes, he's wearing his Mini Mocs. They go well with these PJs!)

Here is Littles modeling another "soft shirt."

I got the t-shirt for this one through a co-op that I'm part of. The co-op organizer found an amazing deal on toddler t-shirts -- it worked out to be about $1.50 a shirt including shipping and everything, so basically the same cost as the underwear shirts at Wal-mart. But these shirts are much higher quality and come in colors. I had this yellow shirt in mind specifically to match these yellow Pooh PJ pants. I also picked up a bunch of pink and blue shirts so that I have them on hand for future projects!

(Yes, those are Mini Mocs on her feet, too! That's a pair that I made a while ago. They are made entirely out of pink fleece, no other materials.)

Littles loves her new "soft shirts." I'll probably make more of these before winter is through!