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Learn to Sew a Flight Suit

Create a professional-looking flight suit in this comprehensive online sewing class featuring the Mercer coveralls pattern. Perfect for intermediate sewists, you'll master techniques for constructing a fitted one-piece garment with sophisticated details. Learn to install zippers, create convertible collars, and construct multiple pocket styles. This class guides you through each step of making a modern wardrobe statement piece with professional finishing touches.

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Prepare to Sew

The Mercer coveralls are a modern classic for your wardrobe that will teach you fundamental sewing skills. This pattern offers a sleek fit throughout, with a straight-cut leg, waist darts, full-length sleeves featuring cuffs and plackets, and a convertible collar.

Mercer has a centered coil zipper and flat front waistband with an elastic back for easy on-and-off. It’s also full of pockets with patch pockets at the chest and back and angled pockets at the sides. With this pattern, you can create a versatile, effortlessly chic garment that gives you the confidence to express your unique style and show off some new sewing skills.

Fabric and Fit

Fabric recommendations: Look for medium-weight woven fabrics such as cotton twill, linen, linen blends, denim, canvas, and corduroy.

Avoid lightweight fabrics as they can’t support all the details. Also, avoid heavyweight fabrics, or the garment will wear really heavy on your body.

Learn to Sew a Flight Suit

Here’s what you’ll need for this project:


  • Mercer pattern

  • All-purpose polyester sewing thread

  • Sewing machine needle

  • 1 yard (.8 meters) of lightweight fusible interfacing

  • One zipper; 20” (51 cm) for misses sizes 00 - 8; 22” (56 cm) for misses sizes 10 - 18; 22” (56 cm) for curvy sizes 12 - 20; 26” (61 cm) for curvy sizes 22 - 30

  • Two 5/8” (16 mm) buttons

  • 7/8 yards (.7 meters) of 1 1/2” (3.8 cm) elastic

  • (Optional) topstitching thread

  • (Optional) topstitching needle

  • (Optional) safety pin or bodkin (Sienna recommends TWO bodkins for this pattern

  • (Optional) Wash-Away-Wonder Tape

Work alongside other sewists by participating in the Seamwork community. Ask and answer questions, share your progress, get inspired by real-life sewists, and post your finished projects.

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