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The Last Stitch | Sew a Buff With a Flatlock Serger Stitch @Thelaststitch | Uploaded January 2021 | Updated October 2024, 3 hours ago.
Learn how to sew a tubular scarf (buff) using a non-chafing 2-thread flatlock seam on a serger.

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Instructions for sewing a buff with a serger flatlock seam

Suggested measurements for the buff pattern piece
Child
Width: 40 cm (15 ¾”) Height: 48 cm (19”)
Adult Small
Width: 46 cm (18”) Height: 50 cm (19 ½”)
Adult Large
Width: 50 cm (19 ½”) Height: 52 cm (20 ½”)

Cut the buff. The width should have the same direction as the most stretch on the fabric.
Cut out the rectangle. Fold the buff, wrong sides facing, right side up. Yes you heard that right, this the way fabric should be positioned when sewing a serger flatlock seam.

Set your serger on 2-thread flatlock seam. Check the serger manual for your machine to see exactly how to set this up.

Before you start sewing your flatlock seam, here are three tips for making this sitch truly flat

Position the edge of the fabric slightly away from the cutting knife.

Either increase the needle tension or decrease the looper tension. This will also help the seam lie flat when opened.

Increase the stitch length to make the seam less bulky. But don't make the stitches too far apart, as it might affect the durability of the seam.

Remember to always do a sample to test the flatlock seam really becomes flat when pulled open.

Make sure there is a 10 cm long thread tail before sewing, you’ll need this tail to secure the seam after sewing.

Stitch the buff, remember the right side of the fabric should be facing you.
Meaning that you are sewing the buff from the outside instead of the inside which is what you do with most other stitches.

Here I’m using flossy woolly nylon for better coverage and a professional finish, to learn more about this thread check out my woolly nylon video: youtube.com/TOlm8oGNx1c

The woolly nylon is a great addition, but you can of course use regular serger thread instead.


When you reach the end of the fabric, keeps sewing
Open up the flatlock seam by pulling it. On the reverse side, you’ll see these ladders. Go over the seam one more time to make sure it really lies flat.

Secure the seam on the reverse side by inserting the thread into the ladders and then finishing it off with a knot or two.

Repeat on both sides and trim the remaining thread.

The finished buff. Look how neat and great it looks, with no chafing seams, so this scarf will be so kind to your skin.

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