Perfect for your budding superstar, these soft and squishy playthings are lovely to kick and roll and throw and catch and even just hug.
This tutorial is an exerpt from Susan Wasinger’s beautiful book: Sewn by Hand.

Here is the tutorial:
Materials
scraps or fat quarters of light-weight
cotton prints (each ball requires
6 different prints)
heavy-duty thread
fabric scraps for stuffing
eco-friendly fill (see note under Fabrics)
bell or rattle (optional)

Tools
standard sewing basket
paper for template
washing machine/dryer
stiff brush (optional)
Fabrics
For the spheres: Since this will be used by a child, organic fabrics would be an excellent choice here. You really only need a few inches of each print, so raid your stash for suitable scraps.
For the stuffing: This is a great project to try eco-friendly fillings like those made of organic cotton, kapok, and bamboo.
Spheres in two sizes, 6 inches or 8 inches in diameter
Notes
Since these soft toys will be getting a lot of love and squeezing and maybe even a nibble or two, the stitching must be nice and tight to keep the stuffing safely on the inside. Use a small backstitch that has virtually no gaps to make it secure. For even more security, do a double row.
Portability factor: { pretty high }
Small pieces, very few notions, sew them anywhere, but leave the stuffing for home.

Prewash all the fabric for this project–very important! Cut out six of the pattern templates in the size you choose (click the image below to open an enlarged size and print the template for use).

The balls are most fun if each section of is a different fabric, so raid your deep stash! Try to position the template at a 45° angle to the grain of your fabric; this will give the best fray. Save all the cuttings and scraps (more on that later).

Wet each cut piece and rub it vigorously between the palms of your hands to rough up the edges as much as possible. Repeat the process until you see the edges start to fray. Once you have roughed up the edges on all the pieces, throw them in the dryer with something rough (like towels or jeans). This will help the edges really “bloom,” creating the soft, fuzzy fray that makes these balls so lovable. Continue the entire fraying process until you are happy with the amount of fray. You can see why it was so important to pre-wash your pieces–otherwise they might all have shrunk to different sizes through all this wetting and drying. Lightly iron your sections so they lay flat, but not so much that you squash the fuzzy edge.

Lay out your sections in a pleasing sequence, alternating dark and light, tone or pattern until you are happy with the effect. Remember that the pieces at the far left and far right will ultimately be adjacent to one another when the sphere is complete.
Lay the first two sections on top of the other with wrong sides facing. Pin then sew along one edge from point to point about ¼ inch or less from the edge, using a backstitch and heavyweight thread. Start and stop about ¼ inch from each point to leave room for the point of the adjacent piece. Knot your thread at the end of the stitching, but no need to cut it as you can use this same thread when sewing on the next piece.
Pin on the next piece to this first group, lining up the points, wrong sides together. Sew as before. Continue until you have attached all six pieces. Leave open the last seam for stuffing.
To give the ball a little more heft than just plain stuffing can provide, bundle some of the fabric scraps and maybe a jingle ball in a small square of scrap cotton.

Squeeze it together into a small ball, then tie off the top with a few stitches and a knotted thread. Wrap stuffing (I used bamboo fiber stuffing) around this bundle and stuff it inside your fabric sphere. Keep adding stuffing until the ball is round and firm. Make sure to work stuffing all around your bundle to keep it in the center of the ball. It is hard to over-stuff these spheres.

Pull the final two edges together and pin. You will need to compress the stuffing a bit to finish this seam, but it will spring back nicely. { photo 4 } Sew the final seam closed. Knot and bury the thread deep inside the ball. If necessary, you can tidy up the apexes of your sphere, where all six points meet, and close it off completely with a few little stitches.

Featured Stitches
Backstitch

Posted by Living Crafts on Jul 29, 2012 11:13 AM | 321 Comments