Make a vegtan leather passport cover with free pdf pattern

TL:DR: pattern and build video are at the bottom of the article.

Keep your passport safe and secure in its very own cover

If you plan on travelling soon or want a secure way of storing your passport until the current pandemic is over, then you may want to read this article, download the free pattern and make your very own passport cover.

The cover will keep the passport from getting dented and damaged, avoid spills, turned pages and, over the years, will prolong the life of this precious document.

Passport cover with free PDF template — Learn to make the passport cover you’ve always wanted with this free PDF template!

Tools and materials needed

Here are all the tools and materials you’ll need to make this passport cover.

3 oz. vegetable tanned leather (1,2mm thickness)
Cutting surface and sharp knife
Passport PDF pattern printed out at 100% original scale
Metal ruler or straight edge
Edge beveller or sandpaper
Leather glue
Pricking irons
Tokonole or other burnishing agent
Optional - lining material
Optional - edge creaser

Git it all? Good, lets get started!

All the steps to making your passport cover

Print PDF file on A4 paper, making sure your printer settings respect the original scale of the document (check Print Guide on the last page)
Cut out paper template and glue the paper template to card stock
Using cut-out template, scribe pattern onto the leather
Cut leather along your scribed lines
(optional) Skive leather around the Card Panel stitch line if necessary
Dress and burnish edges that will not be stitched - Card Panel and inside of Front Panel. (optional) Using edge creaser, add decorative crease lines along these edges
Glue the Card Panel to the Front Panel, along the stitch lines indicated on the sides of the Card Panel
Stitch down the middle part of the Card Panel onto the Front Panel using pricking irons or awl to make the holes
Glue the Front Panel to the Back Panel and let your project sit for a couple of hours till the glue sets
Clean the outer edges to be stitched by cutting a clean edge or sanding until all layers of leather are flush
Mark your stitching line 3 mm from the edge, punch holes for stitching using pricking irons or awl, and stitch
Dress and burnish the outer edges of your project. (optional) Using edge creaser, add a decorative crease line along the edge