Getting Started
So this whole thing kicked off when my niece joined her college rugby squad. They needed custom polos but couldn’t afford the pricey team packages suppliers were pushing. I’m like – screw it, let’s DIY these suckers. Grabbed my old sewing machine from the garage and dusted it off. Looked up rugby polo designs online for hours til my eyes burned.
Fabric Hunting Disaster
Went to three fabric stores downtown thinking this would be easy. Big mistake. First place had “sports fabric” that felt like paper towels. Second shop tried selling me polyester that’d make players sweat buckets. Finally found decent breathable stuff at that family-run spot near the train station – cost twice what I planned though. Got dark blue because white would show grass stains like crazy.
The Pattern Nightmare
Tried modifying a regular polo pattern – total fail. Rugby tops need stretchy shoulder panels for tackling, right? My first three attempts looked like deformed tube tops. Watched rugby matches on YouTube pausing when players got tackled to see how the fabric moved. Ended up:
- Cutting main body pieces 20% wider
- Adding stretch panels under arms
- Making collars extra tight so they don’t flop
Burned through so much cheap muslin practicing that my trashcan overflowed.
Sewing Like a Madwoman
This part nearly broke me. My sewing machine kept jamming on the thick collar seams. Broke seven needles in one afternoon! Cursed so loud the neighbor knocked to check if I was okay. Finally figured out I needed:
- Heavy-duty thread
- Ballpoint needles
- Walking foot attachment
Pulled three all-nighters stitching numbers on backs with iron-on patches that kept peeling off. Pro tip – sew the damn numbers on, don’t trust adhesive.
The Reveal
Delivered them to the team last Tuesday. Held my breath watching girls try them on. They actually fit! Saw them do practice tackles – collars stayed put, seams held strong. Goal kicker complained about sleeve tightness though. Next batch I’ll add stretchier cuffs. Worth every blister and gray hair.
