Route 66 Applique Pillow Project Tutorial

This Saturday, May 23, 2026, the city of Lockport, Illinois is celebrating the 100th anniversary of Route 66. “The Mother Road” (as it is known, isn’t that cool??) stretches from Chicago, Illinois, to Los Angeles, California. It’s an historic, legendary highway that connected our country and sparked a golden era of travel, roadside attractions, and unforgettable Americana.

Lockport is celebrating with commemorative benches placed along State Street—you should make it a point to visit and see them in person! You can learn more about the event this weekend here. When we thought about how we could participate, we immediately saw Route 66 pillows and pillows to show off your zip code in our imaginations. 

We want to help everyone celebrate the 100th anniversary of Route 66! And thus, our project tutorial for the Route 66 pillow and zip code pillow was born. 


Materials Needed

*Required for the black-and-white pillow.

**Required for the red, white, and blue pillow.

Cut:

From Background fabric:

2 - 20” Squares – one for the pillow front and one for the back.

2 - 1½” (or zipper width) x 4” for zipper tabs 


From accent fabric:

1 - 4”X 20” for zipper cover


Optional binding: 

3 - 3.5”x width of fabric


From Woven Fusible Backing:

2 - 20” Squares – one for the pillow front and one for the back.

2 - 1½” (or zipper width) x 4” for zipper tabs 

Materials Needed for Zip Code Pillow

  • ½ yard for pillow background front and back and zipper tabs
  • Black fabric – Fat Quarter for appliques and zipper cover
  • 1 yard of Woven Fusible Backing 
  • ½ yard of Heat and Bond Fusible Interfacing
  • 18” or longer zipper
  • 12” x 18” pillow form 
  • Cotton thread to match all fabrics

Cut:

From Background fabric:

2 - 14”x 20” Squares – one for the pillow front and one for the back.

2 - 1½” (or zipper width) x 4” for zipper tabs 


From accent fabric:

1 - 4”X 20” for zipper cover


From Woven Fusible Backing:

2 - 14”x 20” Squares – one for the pillow front and one for the back.

2 - 1½” (or zipper width) x 4” for zipper tabs 


Applique + Fabric Preparation


1. Prepare the pillow fabric. Iron on Fusible Backing. Press the fusible backing to the wrong side of the pillow front, pillow back, and zipper tabs. It adds stability and structure for a cleaner, more professional finish. Place the rough (glue) side against the fabric. Follow the manufacturer’s instructions. 


Hot Tip: Protect your iron with a towel or pressing cloth—any exposed adhesive can stick to the soleplate of your iron. 


2. Print the templates. Print both the reversed and readable versions. Be sure the printer settings are set to Portrait and Actual size. The width of the entire design across the 6’s should be 10⅜”.


3. Tape the templates together. Align the top and bottom edges of the Route 66 sign, then tape the two template halves together.

     

4. Trace the letters onto Heat N Bond interfacing. The fusible has two sides: a rough, glue-like side and a smooth paper side. Trace the reversed sign image on the paper side. If you’re making the red, white, and blue version, label each shape with its fabric color. I used the Nifty Notions Trace & Trim Studio Lightbox, which has an adjustable, high-intensity light with three brightness settings for easy tracing—even on darker materials. It really helped me see the design for easy outlining.

   

5. Rough cut the Heat N Bond around the shapes. Leave at least ¼” around each shape. On larger shapes, like the sign, cut out the center of the Heat N Bond to eliminate bulk. You will cut them accurately once fused to your fabrics. 

   

6. Iron Heat N Bond on to fabrics. On the wrong side of your fabrics, fuse each Heat N Bond shape to the matching fabric color. If your solid fabric doesn’t have an obvious right or wrong side, either side is fine. If making the red, white and blue version, use blue fabric for the bottom of the sign and red for the top.     

7. Cut out shapes. After fusing, cut out the shapes with sharp scissors. I like Karen Kay Buckley’s Perfect Scissors (7¾"). The micro-serrated blades grip the fabric to prevent slipping, resulting in cleaner cuts and less fraying. The larger handle openings are comfortable for both right- and left-handed users.

   

  

8. Prepare the background and applique shapes. Fold and crease the pillow front in quarters to find the centers. Peel the paper off the shapes to expose the Heat N Bond fusible material. With the readable template under the fabric to use as a guide, place one shape at time.

           

9. Fuse applique shapes to background. Place the readable template under the pillow front fabric to use as a guide. Place and lightly fuse the individual shapes. Once happy with the placement, remove the paper template and iron down the shapes. Fuse each shape separately. 

Hot Tip: PRESS, DON’T IRON so the fabric doesn’t shift and wrinkle. I used a ruler to align the letters. (For the red, white, and blue version follow Step #10 Instruction.)

Skip to step # 17 to complete the pillow.

10. Red, white, and blue fabric placement. The red and blue sections of the Route 66 sign need to be traced onto the Heat N Bond, fused to their fabric, and cut out. The letters, numbers and sign outline use white fabric. 

Hot Tip: When creating applique designs with multiple colors, build your design from the bottom up. 

DO NOT PEEL THE PAPER FROM THE RED SIGN SECTION. Place the red fabric, with Heat N Bond paper still attached on the readable template. You should be able to see the sign shapes through the fabric. Peel the paper from the “ROUTE” letters and lightly fuse to red fabric. Slide the fabric off the paper template and press well. 

     

11. Use an applique pressing sheet to build the remaining applique design. Place the applique pressing sheet on top of the readable template. I like the Applique Pressing Sheet by Bear Thread Designs. An Applique Pressing Sheet is great for all fusible applique designs. It has a non-stick surface that allows the entire design piece to release in one piece!


12. Peel the paper from the back of the red and blue fabric. Align the fabric and lightly press onto the applique pressing sheet.

13. Peel the paper from the “6”s and press into place.


14. Peel the paper from the sign outline. Carefully place, checking to ensure that the red and blue fabric edges are covered. Because the outline is thin, it can be maneuvered into place. Carefully press onto the red and blue fabrics.

         

15. Prepare the background. Fold and crease the pillow front in quarters to find the centers. Peel the completed applique from the applique pressing sheet.

             


16. Fuse the applique to the pillow front. Center the applique design on the center of the pillow front using the creases as a guide. Use a ruler to measure around the design to verify that the design is centered.  Press into place.

17. Stitch. Using the stitch of your choice, stitch down the shapes. I used a straight stitch, with a thread color that matches the shape fabric. Slowly stitch around each of the shapes securing them to the pillow front.

   

Hot Tip: Watch our video on applique stitches to learn how to make 3 different kinds of applique stitches: blanket stitch, zig zag stitch, and straight stitch: 

 

Pillow Construction

1. Square the pillow front to 18” square. 


Hot Tip: If the pillow front and back are cut to the exact size of the pillow form, the pillow will finish with a nice fullness—even after sewing front and back together!


2. Move the zipper pull to the center of the zipper. Trim off the metal zipper stops from both ends.


3. Fold zipper tabs in half, right sides together, and press. They should measure 1” x 2”.


4. Insert one end of the zipper into the fold. Stitch in place.

5. Fold the zipper tab away from the zipper, press and topstitch. Repeat for the opposite end. The zipper pull is still on the zipper. These tabs act as a zipper stop, extend the length of the zipper and give a professional finish.


6. Cut pillow back 6½” from the top.

7. Center the zipper face down on the bottom half of the pillow back. Pin well and stitch. Press the seam towards the pillow fabric.

   

8. Fold the accent strip in half to measure 2” x 20”. Press. Align the raw edge of the accent strip with the top edge of the zipper. Baste accent strip to zipper with a small seam allowance.

9. Pin the top ½ of the pillow back, right sides together, to the accent strip, aligning the raw edges. Stitch. Press the pillow back top away from the accent strip. The zipper is hidden and gives interest to the pillow back.

10. Trim pillow back to 18” square.


11. Open the zipper halfway. 


12. Pin the pillow back and the front together, right sides together.  Be sure the top half of the pillow back is smaller than the bottom half and that the pillow design is facing up. Stitch around the pillow using a ½” seam allowance. Finger press or lightly press seams open. (OR FOR OPTIONAL PILLOW BINDING, SEE INSTRUCTIONS BELOW.)

13. Turn the pillow right sides out. Insert pillow form. Zip and enjoy! 


Optional Pillow Binding

  • Align the pillow pieces, wrong sides together. Pin well and baste with a ¼” seam allowance.

  • Bind using ½” seam allowance.

 


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