Thread Theory

Welcome to the new era of menswear sewing. Go ahead and create something exceptional!

How to Sew a Men’s T-shirt


Thread Theory  How to Sew a Men's T-shirt

Here we are, ready to sew a knit t-shirt!  This post will go step by step through each moment of sewing a men’s knit t-shirt using a basic sewing machine with a zig zag stitch.  This is the third post of the Strathcona
Tee Sew-along featuring our Strathcona Henley menswear sewing pattern.  You could use this tutorial with any basic t-shirt pattern though!

Are you ready to sew?  It won’t take long!


  • Keep in mind that the Strathcona Henley has 5/8″ seam allowances on all seams.  Some t-shirt patterns may have smaller seam allowances than this – make sure to check your pattern!
  • Insert a ballpoint needle into your machine and test your stitch style (check out this post if you are wondering how to choose a stitch style)
  • Reduce the pressure on your presser foot if your sewing machine provides this option – if you are unsure whether it does, make sure to take the time to check your manual.  Reducing the pressure will make handling your knit fabric much easier since it will not become stretched out as you sew.
  • Whenever you start sewing a seam, start with the needle in the “down position” so that it is lowered into the fabric.  This will reduce the risk of the first needle motion punching the fabric into the needle plate of the sewing machine.

Sew the Shoulders

If your knit is quite stretchy, you might like to stabilize the shoulders so that they don’t get saggy over time.  Stabilizing the shoulders will result in a smart looking fitted t-shirt – this may or may not be your style – you choose!

Thread Theory Sew a Men's T-shirt (2 of 55)

If you decide to stabilize, you can use rayon seam binding (as seen above), clear swimsuit elastic, a thin woven fabric strip, or even the selvedge of your knit fabric (you will notice that the selvedge isn’t as stretchy as the rest of your fabric).  The goal here is to choose something that doesn’t stretch much and isn’t very bulky.Thread Theory Sew a Men's T-shirt (3 of 55)Place the t-shirt front and back with right sides together.  Place the stabilizer along the wrong side of the back of the t-shirt.  You will notice that the back shoulder is wider than the front shoulder – it is drafted this way to accommodate for men’s muscular and rounded shoulders!  Stretch the shirt front to match the shirt back at the shoulder seam as you sew.
Thread Theory Sew a Men's T-shirt (7 of 55)

If you are using a very a stabilizer that does not allow any stretch at all, you might as well use a straight stitch for this seam.  The shoulder seams do not need to stretch and they are quite visible so a tidy straight stitch can produce an attractive seam.  If you choose to use an elastic or knit selvedge as a stabilizer you will still want to use a stretch stitch since all of your materials contain stretch!
Thread Theory Sew a Men's T-shirt (9 of 55)

Press the seam allowances towards the back to cover your stabilizer (it is also possible to press your seam allowances open if you would like to reduce bulk).Thread Theory Sew a Men's T-shirt (10 of 55) If you would like, you can finish your seam allowances using another row of zig zag stitching.  This will stop any potential fraying (which may or may not occur depending on the style of knit you choose).Thread Theory Sew a Men's T-shirt (12 of 55)
Trim the 5/8″ seam allowance to reduce bulk.
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Sew the Neckline

Now that the shoulder seams are sewn, you will have a neck hole that is ready to finish with binding!
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With right sides together, join the narrow edges of the neckline binding.  Sew this using a straight stitch (this short seam doesn’t need to stretch either).
Thread Theory Sew a Men's T-shirt (18 of 55)

Trim the seam allowance and press the seam allowances open.
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Finish preparing the binding by folding it in half lengthwise so that the raw edges meet.  Press along the folded edge.Thread Theory Sew a Men's T-shirt (21 of 55)

This is what your finished neck binding will look like:Thread Theory Sew a Men's T-shirt (22 of 55)

Arrange the t-shirt body with right sides facing you.  Place the binding circle on top of t-shirt, alight all of the raw edges.  I like to match the binding seam to one of the shoulder seams but you could also align this seam with center back if you prefer.Thread Theory Sew a Men's T-shirt (27 of 55)If you are using the Strathcona Henley pattern, ignore all the notches on the neckline binding (they are intended for the Henley variation of the pattern).  Pin the binding to the neckline so that it is stretched evenly around the neckline – it might take some fiddling to get this evenly stretched.  I tend to use 8 pins spaced evenly.
Thread Theory Sew a Men's T-shirt (26 of 55)

Stitch the binding to the neckline using a zig zag (or other stretch stitch).  I used to place the t-shirt with the binding facing up on the sewing machine but recently switched my technique.  I now place the t-shirt facing up and stretch the t-shirt with my fingers as I sew.  Try out both ways and see what works best for you!  I find that my new method reduces the risk of creating little tucks in the t-shirt neckline (they are super annoying to stitch rip!!!).
Thread Theory Sew a Men's T-shirt (28 of 55)

Press the finished neckline.Thread Theory Sew a Men's T-shirt (29 of 55)

If you would like, you can finish the neckline by adding a line of stitching around the shirt 1/8″ from the neckline seam to lock the seam allowance in place.  I used a zig zag stitch here but you can up your game for really professional results by using a twin needle (or you can skip this step altogether if your fabric presses well and you don’t think your seam allowance will tend to flip upwards – I often avoid stitching when I am sewing with crisp and thin cotton jerseys but find it is necessary when sewing with thicker cotton interlocks).
Thread Theory Sew a Men's T-shirt (31 of 55)
Trim the neckline seam allowance:
Thread Theory Sew a Men's T-shirt (33 of 55)

I like to trim from the shirt side so I don’t risk snipping into the shirt!

Thread Theory Sew a Men's T-shirt (34 of 55)
Sew the Sleeves

Place the t-shirt and sleeve with right sides together.
Thread Theory Sew a Men's T-shirt (37 of 55)

Line up the shoulder seam with the middle sleeve notch:
Thread Theory Sew a Men's T-shirt (38 of 55)

Place a pin where each notch meets.Thread Theory Sew a Men's T-shirt (39 of 55)

The double notches indicate the back of the garment.Thread Theory Sew a Men's T-shirt (42 of 55)

Sew the sleeve seam using a zig zag stitch (or other stretch stitch).  You will need to adjust often (with the needle down so that the fabric doesn’t slip out of the way) to avoid creating any tucks and wrinkles.Thread Theory Sew a Men's T-shirt (43 of 55)

Finish the sleeve seam allowance with a second row of zig zag stitching and trim.
Thread Theory Sew a Men's T-shirt (46 of 55) Press the sleeve seam.  In the Strathcona instruction booklet I recommend to press the seam allowance towards the sleeves – this is the classic direction to place sleeve seams (as seen on tailored garments).  Lately I have been finding that pressing the sleeve seam allowances towards the garment and away from the sleeve produces a smoother seam more reminiscient of store bought t-shirts.  Try both ways to see which way fits best on the recipient’s shoulders!  Press the sleeve seam on a tailor’s ham or on the narrow curve of the end of an ironing board so as to keep the rounded shape of the seam.
Thread Theory Sew a Men's T-shirt (45 of 55)

Sew the Side SeamsThread Theory Sew a Men's T-shirt (48 of 55)

Pin the sleeve and side seams – make sure that the underarm seam meets.  Stitch using a zig zag stitch or other stretch stitch.
Thread Theory Sew a Men's T-shirt (49 of 55)

Finish the seam allowance with another row of zig zag stitching and trim the seam allowance.Thread Theory Sew a Men's T-shirt (50 of 55)

Press the seam allowances towards the back – your shirt is almost finished!

Thread Theory Sew a Men's T-shirt (51 of 55)Sew the Hems

You can finish the hem as you normally would – by pressing the raw edge up and then pressing upwards again – but you might find that this creates too much bulk for your knit t-shirt to sit nice and casually (it could look fairly stiff with a thick hem).  Alternatively, you could finish the edge by pressing up once at the hem notch:
Thread Theory Sew a Men's T-shirt (52 of 55)

Once pressed and pinned in place, stitch the single layer hem in place using a twin needle, or, as photographed, with a simple zig zag stitch.  Try your very best to keep the knit relaxed – refrain from stretching in any way!
Thread Theory Sew a Men's T-shirt (53 of 55)

Repeat this hemming step for the sleeve hems.
Thread Theory Sew a Men's T-shirt (54 of 55)

And that’s all there is to it!  A nice basic, classically shaped crew-neck menswear t-shirt is ready to wear!


I hope your t-shirt has turned out well!  I will be sharing a blog post on Friday featuring Matt in his finished t-shirts – he’s thrilled to have fresh basics added to his closet!

If you would like to share your Strathcona T-shirts (or any other t-shirts that you sewed while following this sew-along) please use #strathtee so we can see the results!


29 thoughts on “How to Sew a Men’s T-shirt

  1. My husband is constantly buying and wearing T-shirts, but feels they are always too tight around the neck. I’ve tried several ways of turning down the neck binding and top-stitching, but it puckers because of the size variation from the neck edge. Any suggestions? I’ve thought of using old T-shirts and making a new neck binding that would fit the increased size of the neck, but the colors do not always match. He does not like V-necks. Thanks for any suggestions.

    • I think your idea of making a new neck binding is a good one but you would need to embrace the look of a contrast binding! Or, perhaps you could find a brand with a larger neckline – a company that I’ve found to have more relaxed (and in my opinion, more modern and stylish) t-shirt necklines is Canadian online company Frank and Oak. Of course, the neckline size probably varies based on the style. And I would be remiss, as a menswear sewing company, not to recommend that you or your husband try to sew his perfect tee from scratch! Our Strathcona Henley or Sayward Raglan sewing patterns both feature the modern relaxed crew neckline that you are looking for. 🙂

  2. Lovely tutorial!! Brilliant work…. Thanks ThreadTheory.

  3. My husband likes V-neck tees, how to do I finish the V portion without looking bulky or homemade?

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  5. My first comment on a blog…but had to say GREAT TUTORIAL – very clear and easy to follow and my t-shirt turned out great! Thank you!!

  6. What fabric did you use for the neckline and t-shirt? Thanks.

  7. THANKS for this. I have been trying to master knits for a couple of years now and this tells me I am doing it right.. I use these techniques for making a long tee for sleepwear. Only question I would have is what might be the problem when the bottom hem turns upward after sewing and washing? I assume the fix is making a wider hem.

    • The most problems I’ve had with a hem turning upward is when I used a twin needle on a rather thin and stable jersey. The twin needle stitching I did on the hem tunneled a little – it wasn’t noticeable when I ironed the hem after stitching it, but once washed, the tunnel became more obvious and cause the fabric below the tunneled stitching to want to flip up. It still does this, after over a year of wearing the t-shirt when the shirt comes out of the wash. If I quickly flatten the hem while the shirt is still warm from the dryer then the problem is not noticeable. I’ve noticed the hems tend to flip up on storebought t-shirts featuring very stable jersey (without much drape and with quite a tight knit). I wonder if, aside from the twin needle stitching tunneling, it is also the stiffness of the fabric that causes the hems to flip up? What kind of fabrics do you most often notice this on?

      • I did find it doing it on a very firm cotton knit I bought ages ago in a thrift store. Love the color but had to guess at the fabric content. On rayon knits I turn the hem just once and allow it to ripple a little under the sewing so it looks a little ripply. Softer knits have had varied results. I like a narrow hem but haven’t found a method I am happy with. Am redoing some of my earlier efforts.

      • I use a fuse-able knit hem tape.

  8. WOW …..!!!!!
    Really a nice blog explanation about the T-Shirt Sewing Patterns for a good designation of a Shirt.

  9. This is rad, so why do people use an overlocker? this seems way neater and far more efficient.

  10. Nicely and neatly done! Thanks for this.

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  13. I’m a beginner so I apologize if this doesnt make sense – when you say a zig zag stitch – is this half on and half off? Or is it fully on meaning you would then have to trim the excess?

    • Hi Ashley, No problem, I remember wondering the same thing when I began to sew! Sew fully on the fabric. You can trim the excess seam allowance if you would like to make it less bulky but it really isn’t necessary :). Don’t hesitate to email ( or comment if you have any more questions!

  14. I like your steps, it’s gives me every thing I need to know. Thanks

    Pls I’m a beginner in sewing, if I can get some videos abt sewing I will be very happy. Thanks

  15. Thank you so much

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  19. Nice tutorial with very helpful hints! Here are two of my additions. I find the the seamline on the side can sometimes shift quite a bit between careful pinning and a mismatch that’s a pain to unpick. I pin and sew a two inch straight stitch seam with a looser but not basting stitch at the underarms. If the alignment is spot on I’m good to go if not it’s not much to unpick for another try. The second is using a trim on the back neckline much like you suggested for the Finlason.

What do you think? Leave a comment for me :)

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