Cover image – the pogies are stable and accessible…even when just bike-pushing. :) Each pogie weighs less than 115 grams.
This post outlines creating a simple cardboard cutting template, and sewing a pair of warm lightweight pogies for cold weather riding . The main differences from commercially available pogies are the Velcro mounting and front closure/venting system, and the potential to upcycle worn out synthetic insulated outerwear. Each pogie consists of two halves. Each half consists of an outer and inner fabric layer with insulation sewn in between. The two halves are then joined and finished with edging and Velcro. The pictured pogies have seen hundreds of uses since Fall 2021, while undergoing several minor changes to accomodate cockpit tweaks such as a dropper post lever cable, and rotary shifter cabling. Apologies for the lack of sequential contruction pictures. This was a learning by doing project. :)I’ve included pictures and comments on design changes, in hopes that others can avoid them.
If you just want to buy some really warm pogies, check out the ones my friend Doug Coldbike makes!
Image of the completed “first draft” version, without a drawstring closure.
Notes on key sizing and shaping requirements. The underlying cutting sheet is graduated in inches.The space for a hand warmer is very useful when riding in high wind chill conditions. It helps keeps the brakes functional below -40.The same template is used to cut all six panels. Finding the correct bar angle sweep is important. Consider making the template larger than needed to provide some room to reduce certain dimensions, or to slightly alter angles. The sizing of this example has been altered to include the narrow VX21 strip mentioned below.
This mens size medium puffy has enough material to cut four panels. One from each sleeve, and two from the back. The front face with pockets and zippers can be used for augmentation or other projects. Materials such as this will require stiffening at the inner and outer edges to retain the pogies desired shape. The string trimmer line pictured below is ideal for stiffening in the bias tape edging.
Cutting Apex Climashield 7.5 (oz/sd yd) insulation with the single cardboard template that all panels are cut from. Apex is made from continuous filament polyester fibres. This insulation helps give these pogies more inherent structure than a typical upcycled Primaloft garment may have.
Examples of finishing materials that were used. Smaller quantities may be available to you locally.
Loop velcro additionHook velcro additionJoining the three layers of each panel
Two halves of a pogie. DP Light Skin 07 outer, HyperD300 inner, Apex Climashield insulation all cut from a single cardboard template. (left) The black strip is hook Velcro. (right) The matching loop Velcro [not visible] is sewn to the other side of the panel.
The two halves of a pogie sewn together with bias tape edging. The extra length is to cover the forearm which helps with warmer blood circulation to the hands.
First weigh-in. The arm hole was too small to accommodate a heavier cold-weather jacket. Oops! I had to immediately add a panel to the upper edge to increase the circumference.
Checking the sizing of the added VX21 panel.More checking.Adding a fabric panel to make the design more functional.
Completed pogie with a panel of DP VX21 added. The VX21 is only a single layer, however the pogies are the warmest I’ve ever used. The VX21 was a fabric remnant just waiting to be upcycled.
The Velcro front closure around the handlebar and rear brake hose, which can be opened if hands are too warm. The handlebar has a patch of Industrial Loop Velcro wrapped around it, and the pogie has a length of OneWrap that engages with the handlebar Velcro patch. This system allows for precise adjustments of the position of the pogies to suit a rider.
Adding a Kam Snap closure flap to keep snow out when not riding.Inside view of the same flap.Closure flap, and weigh-in with the modifications.
The closure flaps proved to be ineffective at keeping drifting snow out. I switched them out for a drawstring closure, also from remnants. The added length reaches almost to my elbows.
Close up of the attachment OneWrap with the patch of Industrial Velcro immediately below the brake lever clamp.January 2024 – worn out OneWrap replacement. A single bar tack is enough. Test fit the pogies before sewing on the OneWrap. The position of the bar tack needs to make it easy to install and remove each pogie.
While riding narrow singletrack my hands were getting beat up by the bushes. This string trimmer line is being inserted into the outer bias tape to provide some stiffening and protection. The cut ends were melted a bit to reduce wear points. The lighter trimmer line pictured earlier in this post also works well. Two strands can be used if desired.
January 2024 repair. The left pogie had some wear-through where the end of the Ergon grip is in contact. A short length of 2″ webbing is being added for protection. Looks like it might be time for a first wash. :)
Out for a training ride on an extremely cold and windy day.
Thanks for reading! Hope you find this post helpful in your DIY practice.
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