I've been working on a karo step down jacket for the last couple weeks now. I started with the Vuokatti Pullover pattern from shelby fabrics and modified to make it bigger since this isn't a stretch fabric and i don't want it skin tight. I'll be adding a full length zipper, two lower pockets and a chest pocket. I'm using m90r which seems to be the exact same fabric that i have on my Outdoor Research down jacket. I have 3 oz of 900 fill down from thru hiker to fill it it with once i get there. Right now i'm in the process of making the baffles which is taking forever. I'm using a 1/4" ratio. I did some test pieces and the down seemed to stay where it was with that low of a ratio. I'm hoping to have about 1.5-2 inches of loft.
Michael

karo template:

marked out arm:

completed arm:

Edited by Mpap89 on 12/10/2011 00:18:40 MST.

4" box with 1" baffles? Is that what 1/4" means?

-Tim

Yeah

Good idea with the template. That must be really time consuming to sew so many tiny baffles. Keep us updated on progress. Which things worked, which didn't, thoughts on box size after you finish, etc.