DIY Upcycled Carhartt Tote Bag: A Step-by-Step Guide

Updated at: 26/03/2025

Carhartt workwear, known for its rugged durability and timeless style, often finds a second life long after its original purpose is served. Instead of letting those worn-out jackets or pants gather dust, why not transform them into something equally useful and stylish? This guide shows you how to upcycle your old Carhartt clothing into a sturdy, one-of-a-kind tote bag, perfect for farmers' markets, grocery shopping, or everyday use. The unique texture and inherent strength of Carhartt fabric make it ideal for this project, resulting in a bag that's both visually appealing and built to last.

This DIY project is surprisingly straightforward, even for beginners. You'll be amazed at how easily you can breathe new life into your beloved, but worn, Carhartt garments. Ready to get started on creating your own custom tote? Let’s dive into the step-by-step instructions below!

Preparation and Safety Guidelines

Tools Needed
  • Old Carhartt trousers
  • Fabric scissors
  • Ruler
  • Iron
  • Seam ripper
  • Sewing machine (or overlocker)
  • Pins
  • Matching thread
Safety Guidelines
  • Always use sharp, clean scissors or rotary cutter when cutting fabric to prevent injury and ensure clean lines.
  • If using a sewing machine, ensure it's properly threaded and the needle is appropriate for the fabric weight to avoid breakage or damage to the material. Always operate sewing machines with care and awareness of moving parts.
  • When working with upcycled materials, inspect for sharp edges, protruding hardware, or any potential hazards before handling. Properly clean the fabric before beginning the project.

Step-by-Step Instructions

  1. Prepare the Tote Body

    • Cut straight across the leg of the trousers, leaving excess fabric. Use the bottom of the leg for the main body of the tote bag.
    • Cut along one side seam to create a rectangular piece of fabric for one side of the tote bag. Repeat for the other trouser leg to get an identical piece.
    • Iron out the fabric to remove creases, then use a ruler and fabric cutter to trim excess fabric on all four sides. This creates a neat rectangle for each side of the tote bag.
    Iron out the fabric to remove creases, then use a ruler and fabric cutter to trim excess fabric on all four sides. This creates a neat rectangle for each side of the tote bag.Iron out the fabric to remove creases, then use a ruler and fabric cutter to trim excess fabric on all four sides. This creates a neat rectangle for each side of the tote bag.
    Prepare the Tote Body

  2. Create the Handles

    • Cut fabric from the thigh area and potentially sew together multiple pieces to reach the desired handle length. Use a ruler and fabric cutter to ensure straight edges.
    Create the handles: Cut fabric from the thigh area and potentially sew together multiple pieces to reach the desired handle length. Use a ruler and fabric cutter to ensure straight edges.
    Create the Handles

  3. Add the Carhartt Pocket

    • Deconstruct the back pocket (with logo) and re-sew it onto the front of the tote bag. This adds a unique deconstructed look and a functional pocket.
    • Sew the pocket onto the tote bag, carefully matching the lines and thread color. Double stitch at the beginning and end for durability.
    Sew the pocket onto the tote bag, carefully matching the lines and thread color. Double stitch at the beginning and end for durability.
    Add the Carhartt Pocket

  4. Attach the Belt Loops

    • Cut off belt loops and sew them onto the top of the tote bag, mimicking the back of Carhartt trousers.
    Attach the belt loops: Cut off belt loops and sew them onto the top of the tote bag, mimicking the back of Carhartt trousers.
    Attach the Belt Loops

  5. Attach the Handles

    • Sew the handles together, aiming for straight lines. The fraying of the fabric adds a distressed look.
    • Attach the handles to the inside of the tote bag, stitching a rectangle for secure attachment.
    Attach the handles to the inside of the tote bag, stitching a rectangle for secure attachment. Attach the handles to the inside of the tote bag, stitching a rectangle for secure attachment.
    Attach the Handles

  6. Sew the Tote Together

    • Sew the front and back pieces together, making sure they are inside out to prevent the bag being the wrong way around.
    • Pin pieces together and use an overlocker (or sewing machine) to stitch the sides and bottom of the bag. Trim excess threads.
    Pin pieces together and use an overlocker (or sewing machine) to stitch the sides and bottom of the bag. Trim excess threads.
    Sew the Tote Together

  7. Finishing Touches

    • Turn the bag right side out, puff out the corners, and you're finished!
    Turn the bag right side out, puff out the corners, and you're finished!
    Finishing Touches

Read more: DIY Vibrant Car Organizer: A Step-by-Step Quilting Tutorial

Tips

  • Leave extra fabric when cutting, just in case of mistakes.
  • Take your time to ensure straight lines when cutting and sewing.
  • Use an overlocker for stronger seams, but a normal sewing machine will work too.

Common Mistakes to Avoid

1. Uneven Cutting

Reason: Using a dull or inappropriate cutting tool, or not paying attention to the cutting line can result in uneven edges, making the final product look unprofessional.
Solution: Use sharp fabric shears and carefully follow the marked cutting lines to ensure precision.

2. Improper Sewing Machine Tension

Reason: Incorrectly adjusted sewing machine tension can lead to puckering, loose stitches, or skipped stitches, ruining the finished look and potentially the integrity of the bag.
Solution: Test the machine tension on a scrap piece of fabric and adjust accordingly before working on the actual Carhartt fabric.

FAQs

What kind of Carhartt clothing is best for making a tote bag?
Sturdy fabrics like denim or canvas from jackets, pants, or even overalls work well. Avoid using very thin or heavily worn-out material, as it may tear during use.
What tools and materials do I need besides the Carhartt fabric?
You'll need strong thread (matching or contrasting your fabric), sewing machine (or needle and thread for hand-sewing), scissors, measuring tape, pins, and optionally, a zipper or additional fabric for lining and reinforcement.