Now you have to get to work, heh?

thank you so much. I have been wanting to know how to do this as I have some pouches to make up. I am almost disappointed that the mystery is gone!

If you give the boxing for the zipper an extra inch and fold stitch that inch into the seam allowance, you should come out o.k., sometimes it doesn't exactly and you have to trim it up.

Thanks so much for the tip.

oh zippers! the bane of all m sewing projects.

Thought I'd note here the baste in step 2 calls for 1 inch of seam allowance each (ontop of which you sew your zipper). Otherwise, just be sure to trim the finished box peace to match the rest of them!!!!! I learned the hard-ish way.