Aviator Nation Knockoff

Appliqué a Sweatshirt & Create a Designer Look for Le$$!

An Aviator Nation Knockoff Sweatshirt will be the hit gift under the Christmas tree this year for any tween, teen, or young adult. Aviator Nation is a popular brand known for its retro-inspired sweatshirts and sweatpants that capture a laid-back California beach vibe. The company uses premium materials and manufactures its products in the USA—qualities that come with a luxury price tag. When my daughters added Aviator Nation sweatshirts to their holiday wish lists, I knew I couldn’t (and wouldn’t) pay $189 or more for each one. So, I put on my “sewing thinking cap” and created a knockoff version so close to the original, no one will know the difference!

Read on to learn how to make this high-end look for a fraction of the cost. Using simple appliqué techniques, I’ll show you how to create those signature vintage-style stripes and perfectly worn-in details with just a bit of fabric, fusible web, and your trusty sewing machine. Best of all, you can personalize each sweatshirt with your favorite colors and design placement. That’s the true beauty of sewing—we don’t have to buy the look when we can make it ourselves!

AVIATOR NATION KNOCKOFF SUPPLIES

• Sweatshirt of choice (a hoodie is most appropriate for the Aviator Nation look, but a crew-neck or zip-up also works)
• (4) contrasting or coordinating jersey knit fabrics (for appliqué stripes; amount needed depends on chosen look)
• (4) spools of Sulky 50 wt. Cotton Thread (colors to match appliqué fabrics)
• Sulky Perfect Appliqué Fusible Web
• Size 70/10 Jersey Needle

APPLIQUÉ PLANNING & SWEATSHIRT PREP

First, wash and dry the sweatshirt and all fabrics to remove sizing. Do not use fabric softener.

Remove the stitching from the sweatshirt side seam, sleeve/armseye and/or shoulder seam. You can remove the entire side seam stitching along one side, except for the lower-edge band, in order to access the sweatshirt front easily for appliqué stitching. Or, only remove the stitching along the seams where the stripe ends will be inserted. If working with a zip-up hoodie, you’ll only need to remove the side-seam section at the sleeve where the stripe ends will be inserted, as you can access the entire hoodie front by unzipping it.

Next, determine the type of stripes and appliqué placement you desire on the sweatshirt. Some Aviator Nation sweatshirts have narrow horizontal stripes, while others have wider wavy stripes. For the featured sample, we’ll plan wider wavy stripes that begin inside one shoulder upper-edge seam and extend into the opposite armsceye side seam, 3″ below the shoulder seam into the sleeve seam.

TO CREATE WAVY STRIPE APPLIQUÉ TEMPLATES

Place the sweatshirt right side up on a flat work surface. Position a piece of transparent paper (Sulky Soft ‘n Sheer Stabilizer also works well for this) over the sweatshirt appliqué area. Secure in place using KK 2000 Temporary Spray Adhesive so nothing shifts.

Using a pencil or fabric marker, draw the wavy stripes onto the paper or stabilizer. For the featured sweatshirt, draw four 1 1/4″-wide stripes that abut along the long edges. The length of each stripe should extend 1/2″ beyond one upper shoulder seam and 1/2″ beyond the opposite armseye side seam.

Label the stripe templates with numbers to denote which stripe goes where (i.e., 1, 2, 3, 4, or upper, upper mid, lower mid, lower).

 

Next, transfer the mirror image of the stripe outlines to the paper side of Sulky Perfect Appliqué Fusible Web. Cut out each stripe from the fusible web.

Fuse each stripe piece to the wrong side of each knit fabric, paying attention to the color gradient to ensure the desired stripe is cut from the desired fabric color.

Then, cut out each fabric stripe along the marked outlines. TIP: Wavy stripes are best cut using a rotary cutter to ensure clean edges.

TO CREATE NARROW STRIPES

Aviator Nation sweatshirts that have narrow stripes are typically done on zip-up hoodie sweatshirts (and also on pants along the side seams). To create these stripe appliqués, draw five ½”-wide stripes onto the paper side of Sulky Perfect Appliqué Fusible Web. The stripe length should measure the sweatshirt-front measurement from armsceye to armseye side seam, plus 1″. If working with a zip-up hoodie, you’ll need 10 stripes, measuring 1/2″ x the sweatshirt front from armsceye side seam to center-front zipper seam, plus 1″.

Cut out each stripe from the fusible web.

Fuse each stripe piece to the wrong side of each knit fabric, paying attention to the color gradient to ensure the desired stripe is cut from the desired fabric color.

AVIATOR NATION KNOCKOFF APPLIQUÉ

Remove the paper backing from each appliqué stripe.

Place the fabric appliqué stripes onto the sweatshirt right side, making sure the colors are placed as desired.

When happy with the placements, fuse each stripe in place with a low-to medium-temp iron.

Next, thread a size 70/10 Jersey Needle with the thread color that matches one stripe. Set the machine for a 3.0mm straight stitch. Stitch just inside the stripe cut edges, making sure to abut the stripe edges with the adjacent sweatshirt seams.

TIP: If desired, choose a blanket stitch or other decorative stitch to secure the appliqués. The result will look less like an Aviator Nation sweatshirt, but it’ll have your unique spin!

Repeat to stitch each stripe appliqué, swapping thread colors with each stripe color.

FINISHING

After each appliqué is stitched, it’s time to restitch the side seam(s) and upper-edge shoulder seam – wherever the sweatshirt was taken apart.

If using a standard sewing machine, set it for an overlock stitch. With the Jersey Needle still in the machine and thread that matches the sweatshirt in the needle and bobbin, stitch the seam edges with right sides together.

Be sure to follow the original stitching line, encasing the “new” appliqué fabric edges in the stitching.

Put on the sweatshirt and strut your stuff, knowing you saved at least $120 by making this fashion-forward sweatshirt knockoff! (Don’t forget to wear a pair of aviators!)