Sewing puffballs in the 80s!

If you’ve ever read the ‘a bit about me’ page here on the blog you’ll see that in the mid 1980s I worked for a bridal and evening wear company in London called David Fielden. I left the London College of Fashion in the summer of 1985 and started working there on my 23rd birthday. Originally I’d wanted to be a costume designer but during my college course I realised that going into bridal or evening wear was a very good alternative. In those days you just sent letters and CVs out to companies you were interested in working for in the hope that they might like the sound of you and be desperate to add you to their payroll! As it happened my letter was passed to Caroline who was the production manager for David in the evening wear workroom and she had done the same course as me a year earlier so she had a fair idea of what I was potentially capable of.

‘trying on’ one of the dresses back in the day…that was fabulous gold-printed panne velvet but it shed everywhere and bits of gold fibre stuck to you! I’ve written on the back that it’s style 668D (the D denoted a dress) in April 1986

They took me on and I was going to be cutting samples rather than sewing which initially I was disappointed about. I soon learned that cutting was a huge responsibility in its own right. I was used to making my own clothes with inexpensive fabrics which I bought in my local market or fabric shops, now I was working with fabulous silk taffeta, dupion, Duchesse and slipper satins, velvet, beaded and embellished brocades, even the lining was always silk habutai, it was all a bit dazzling and quite scary to start with! I was provided with a massive pair of shears which soon gave me a callous on my finger joint, I still have a mark there to this day. We had two huge waist-high cutting tables with all the fabrics stored underneath. The pattern cutter would pass me the initial pattern to cut as a toile so that she and the designer could assess the shape and fit on the stand. When they were happy I would be given the pattern along with all the fabrics and instructions for the new sample. It was part of my job to get everything out of the fabric as efficiently and cost-effectively as possible so I always spent time working this out like pattern Tetris before going near it with the scissors! I kept sketches of the layplan for future reference too. No piece was ever cut on a fold, we always used a whole front or a whole back, sleeves, bodice pieces or skirt panels could be ‘flipped’ though to fit them in. The pattern cutter would make the pieces in card from the paper version and I would draw around them in chalk or marking pencil, the pattern pieces would be held down on the fabric with long heavy weights, this means the pattern lasts much much longer than a paper one would. The card patterns would be grouped in style number order onto large hooks a bit like safety pins, each size was on a different hook. Some styles got informal names which is what we identified them by in the workroom, for example there was the ‘Doris Day’ which was a pretty 50s-style gown with silk satin boned bodice and clouds of diamante-studded ankle length tulle skirts, it came in soft pastel colours, and the ‘Carmen Miranda’ which was a longer length figure-hugging silk bodice overlaid with sequin-embellished lace and extravagantly ruffled silk organza mermaid skirts. This was one of the best selling designs and came in a variety of colours including black and scarlet, or could be ordered in other colours and fabric combinations by special order. Just one outworker made this style because she became so skilled at it, every ruffle was edged using a rolled-hem foot and it was then sandwiched between diagonal skirt panels. Oh and there were net petticoats under all of that too! It was very popular for magazine shoots because of it’s ‘film star’ quality and we were regularly squashing dresses unceremoniously into boxes or into dress bags to be couriered on the back of motor bikes to Fleet Street! Some of those poor dresses really suffered and looked quite tired in the end.

Actress Stephanie Beacham wearing a gown similar to the Carmen Miranda in a women’s magazine
another version of the dress in an ad for a car (?)
Anita Dobson was a huge star in Eastenders on TV at this time
Actress Koo Stark, I remember this being an Ottoman jacket (a type of fabric with heavy ribbing) and separate spotted tulle skirt. The edge of the ruffles were finished with the plastic ‘wire’ stripped out of Rigilene boning and zigzagged onto the edge to make them stand out like this!
This is Kathy, who is Sir Ian Botham’s wife, modelling one of the most popular designs. It’s a pity you can’t see the back as it’s cut away to reveal the small of your back and shoulder blades. There’s a scrap of the fabrics pinned to the picture, it was silk chiffon covered in paillettes over a layer of silk satin and lining, all the edges were finished with bias binding so that the sequins didn’t cut the wearer to ribbons! The skirt is silk organza with a net underskirt.
the same dress worn by Bridget Nielsen, Sylvester Stallone’s then-wife
Same dress again, I think this was editorial in a magazine

Whilst the showroom was in the King’s Road, Chelsea at that time the evening wear workroom was set up across town in Farringdon around the corner from now-trendy Exmouth Market, it was definitely not glamorous and the Woolworth’s pick-n-mix counter was the only interesting eatery back then!!

As well as Caroline, who is still a friend all these years later, there was a designer (David didn’t design, he had no drawing or making skills, he employed others to do it for him) a highly-skilled pattern cutter, a sample machinist and a sample cutter (me) When I wasn’t cutting and costing samples and special orders, Caroline and I would cut production too which was all sewn by out-workers who came in regularly to drop off the garments they had made and to collect the next batch, they were paid an agreed piece rate per garment. Each one was a highly skilled, and fast, machinist who would make the whole garment from start to finish. They all had different capabilities so some would stick to simpler garments like skirts or bodices whilst others made the fantastic evening gowns and ball dresses which David Fielden had become known for. Some of them worked in their own homes and didn’t make a massive quantity of garments, and a couple had set up their own workrooms where they then employed a few extra machinists so they could make larger quantities, we are still only talking about several dozen garments per week though, not hundreds or thousands.

Twice a year the designer, Charlotte, would go with David and his business partner Walter to various fabric shows such as Premier Vision to select beautiful fabrics for the next collection. A lot of the fabrics such as silk taffeta, dupion or Duchesse satins would come from local London suppliers in very quick time, often the same day if the colour was in stock, but the premium fabrics from France or Italy would be ordered in sample lengths ranging from as little as 3 metres up to 10 or 20 metres in the new seasons colours. If those styles then went into production then larger orders would be placed at a later date.

Each new collection was often an evolution of the previous one with a few of the most popular styles being developed in new colours and fabrics, plus some completely new styles. It was always exciting to have the new fabrics starting to arrive from overseas, there were some exquisitely beautiful embellished laces and tulles, occasionally further down the line one or two would prove problematic because the supplier couldn’t produce them quickly enough, or in the quantities required. Each ‘piece’ of lace often came in a 5m length which didn’t go very far. My least favourite fabrics to cut were slipper satin or chiffon, they moved about like the very devil and often it was best to sandwich them between two sheets of spot and cross paper.

Short dress with a velvet bodice and ‘rolls’ of velvet on the shoulders, hip and hem (I wish I could remember what went inside the rolls, it could have been wadding)
It may not look it but this was the most expensive fabric I ever worked on costing around £125 per metre back then! It was a base fabric of lace which was embellished with sequins. THEN it was covered in another more open lace fabric and over-sprayed with gold so that it left a stencil-type design. It came in just 3m pieces if I remember rightly.

I would cut everything for each garment as required and then make a ‘bundle’ including all trims (covered buttons, zip, piping cord etc) and labels. All the cut pieces were folded neatly and layered up and then the whole bundle was carefully folded in several layers of tissue paper and tied up along with identifying sticky labels for the outworker to use when they returned it to us in plastic cover.

Once the new collection was underway Caroline would sew samples as well to speed the process up. Models would come in periodically for fittings and to assess a design on the body. As well as cutting the new samples I also cut one-offs and special orders which could be interesting. For example, we made the gown that Sarah Brightman wore to the party after the world premier of Phantom of the Opera [we memorably made another dress for her to wear for a Gala at the Royal Albert Hall, she had a fitting at the showroom and declared it should be taken in which we duly did at the workroom. It was delivered back to her but with only hours to spare she realised she now couldn’t inflate her lungs to actually sing in it!! Back to the workroom it came to be let out again!] I cut gowns for Daryl Hannah (star of Splash with Tom Hanks) allegedly for the Oscars but I never saw her in it, and I cut a dress for Aretha Franklin too but I never saw that one photographed either. Sadly we never got to meet any of the celebrity clientele, we would just get a set of measurements and fittings would usually take place at the shop. Some stars would borrow gowns for swish parties and premiers so nothing much changes does it? Vogue magazine especially commissioned a version of one dress for a shoot, it was a black taffeta column gown with a wide pale pink sash as I recall. When it returned to the workroom afterwards the hem was water-marked and full of sand! It had been photographed on a beach!!

Dame Joan Collins with her then-partner Bill Wiggins. The dress was a beautiful rose pink colour, I think it was the teensiest bit snug on her.
Dame Shirley Bassey, that ruched bodice and skirt took so much fabric!
a black and white studio shot of the same style that Joan Collins was wearing, this sample was made in beautiful French printed silk taffeta, there was a large puffed bow on the back.
and another version in shot silk taffeta
I remember cutting this little dress, it was made especially for the photo
I think style was being made when I first went to work at David Fielden.

There were times of stress and all-hands-on-deck but lots of laughs too. I have very positive memories of my 3 years at David Fielden, we were a good team and I learnt so much from my colleagues, they were all brilliant at their jobs with so much experience under their belts already. The company was growing fast during those three years and David took on catwalk shows at London Fashion Week (that was very stressful for everyone because of the workload and short lead times involved!) David and Walter travelled to many overseas shows to exhibit which garnered orders from prestige stores in the US such as Neimann Marcus and Bloomingdales among others, stores in Europe, and Harrods in London. [we could have cried though to see these beautiful dresses being crammed into boxes for despatch]

In the end I left after three years because I got fed up with commuting into London every day, I went to work in the dress fabrics department of our local John Lewis branch so that was more textiles and cloth knowledge to store away in my brain to come in handy another day. I’m sorry the quality of the pictures isn’t great, the cuttings were all torn from magazines and newspapers at the time so they are a little tatty in places.

David Fielden is still in business I believe although the premises have moved to Fulham now, I think they specialise entirely in bridal wear but I’m not sure. The website isn’t particularly up to date but you get an flavour.

This turned into quite a long post (I hope you had a coffee in hand?!) but there’s a few pictures to look at too!! I’ve really enjoyed thinking back to my early working days to tell you all about them and I guess I was very fortunate to work with such a variety of very beautiful fabrics, maybe now you can see why I’m always SO particular about cutting out at the start of any project! So until next time,

Sue

New Trend pattern TPC26 plus tips for handling a tricky fabric.

Firstly, I probably need to give you a quick explanation of why I’m making a fancy frock during the lockdown because it must seem rather incongruous.

This is my first post as a Lamazi Fabrics blogger and before the Covid-19 pandemic reared it’s ugly head I had offered to make an outfit using a slightly ‘tricky’ fabric in order to share a few hints and tips for sewing with it. I selected the beautiful Tencel/Cupro ‘Bark’ fabric in Lavender because we were going to a wedding in late May which would be the perfect chance to make a something using this special fabric. Very sadly that wedding is now postponed indefinitely but I’m making the dress because I’ll still need something to wear when it’s rescheduled. 

The fabric has a lovely weight and handle which makes it drape really well. It’s has a bark-like finish and is different on each side, you could use this to your advantage if you want to create an interesting visual effect by having some pieces with one side out and some using the reverse side. 

I made life harder for myself by choosing the new Bias T-shirt Dress by Trend patterns (generously gifted to me by them) in which EVERY piece except the sleeves are singles and strange shapes which means you cut everything out on a single layer of fabric right side up (RSU). Unlike most patterns, when you are cutting pairs of parts you can usually flip a piece without too much difficulty, however if you do that for a piece which must be cut RSU you would have completely reversed the print/design to the wrong side when you try to sew it up. This Tencel/Cupro has a nice look whichever side you use but my advice is to be really careful on printed fabrics before reversing any piece labelled RSU. 

Next, when cutting slippery or fluid fabrics (unless you have a lovely big cutting table) you’ll need to handle them as little as possible (by which I mean pulling them about to get them into position) which might be easier said than done. I know that cutting out is most people’s least favourite part of sewing but it’s so important to take time and care at this stage. If you’re cutting out on a table with straight sides use the edges as a visual marker to get the end of your cloth at a right angle to start with, ensure the weft (across the fabric) is nice and straight as well as the warp, pull a few threads to find the grain if necessary. If you have more cloth than will fit on the table in one go you could try having the excess rolled on a cardboard tube if you have one to keep it under control rather than sliding off the table all the time. 

Because my pattern has large awkward-shaped pieces cut from a single layer I had no option but to cut out on the floor! This can be physically quite tiring so you might want to get help if you need to. This is slippy slidey fabric so an extra pair of hands could help you lay it up nice and straight, again, rolling the fabric onto a long cardboard tube would also help keep the fabric taut and straight as you lay it out on the floor. This is not a fabric to use weights and a rotary cutter on unless the whole lot fits onto a cutting board without disturbing the fabric, if you’re spending time laying up the fabric carefully so that the grain lines are straight in both (warp and weft) directions you can’t then mess it about shifting a cutting mat underneath it and the pattern pieces need to be secured in place with pins. Cut out carefully moving the pieces as little as possible and try to keep them flat after cutting until you’re ready to sew. All of this will help minimise the pieces stretching out of shape, especially as a lot of this pattern has seams running on a diagonal. 

I felt that the length of the dress would probably be too long for me so I took some of the length out of the skirt pieces before I cut them out in fabric.
I calculated that approximately 5 cms would be sufficient to take out of the length so first I drew a line at a right angle to the grainline, then a second line 5cms from the first.
I pinned each piece to it’s ‘partner’ so that I could see if it would still align correctly after I folded out the 5cms.
It was really just educated guesswork but, eventually, by folding out the 5cms horizontally from each panel I was reasonably confident it would be pretty close.
Why didn’t I just take it off the hem at the end? You could easily do that but because I had just 2.5m of fabric, which may not have been quite sufficient, I could not take that risk so I did it this way instead. It took longer but removed the element of uncertainty.
This is almost everything laid up on the floor, I cut a linen version at the same time which is what you can see on the top. Whilst a single layer is often a very economic way of cutting fabric it’s usually more time-consuming to cut out so I did the two at the same time which was slightly risky but it worked out.

Once I’ve finished cutting out it’s vital to transfer all notches and mark darts and a couple of pivot points so I use old-fashioned tailor’s tacks (obviously you can use a textile marker pen if you prefer, I often do but it’s a pale fabric and I didn’t want to risk any marks being left) It’s a habit of mine to keep all the pattern pieces attached by just a couple of pins to the fabric until I need it, so that I don’t them get muddled. These are curious-shaped pieces so the chance of having them the wrong way round could be quite high! Next I stay-stitched all the neck edges on the machine 5mm in, if you have a very loose weave fabric it would probably be sensible to stay-stitch the bottom edge of the front bodice piece to prevent stretching. If you’re using a particularly fine fabric like chiffon you should stabilise the neck, and any other seams which could stretch, by hand-stitching very narrow cotton tape or ribbon over the seam line on the wrong side of the fabric. When I worked for bridal designer David Fielden many years ago we would cut the selvedges off the silk habutai linings for the seamstresses to use on necklines.

There is just a little fraying on the cut edges which I overlocked singly as I went along, as per the pattern instructions. Whether you’re sewing or overlocking the fabric I strongly suggest you have the whole piece supported on the table in front of the machine rather than feeding up from your lap. This is to prevent the piece becoming stretched as you’re sewing and possibly causing it to become misshapen.

If you find, as I did, that there’s a slight discrepancy between two seams (assuming that it isn’t an error in cutting or adjustment of the pattern) then pin it with the excess on the underside so that when you sew the feed dogs will take up the ease.

You can see the lower layer is a little longer than the top one and by sewing it with this on the underside means the feed dogs should take up the excess.
After sewing but before pressing it looked like this.

My photos should make it clearer, a good press will help steam out some of the excess too. Also, to minimise the risk of making a shiny patch on the fabric make sure you use a pressing cloth, you can often buy silk organza ones although I have a piece of plain fine pure cotton lawn which I’ve overlocked around the edge. I use this when I’m pressing darts or turning points or corners out too.

To sew an invisible zip into the diagonal seam across the back I machined the seam closed but I used a long basting stitch just for the section where the zip will go. This stitching will be removed later.

Line up the teeth with the basted part of the seam, this has been lightly pressed open already.
Pin the zip tape to the seam allowance with the seam and teeth matching.
I prefer to tack the tape to the seam allowance at this point but you could use Wonder Tape if you have it.
Now I removed the basting stitches and sewed the zip in using an invisible zipper foot. The zip I was using was longer than I needed.
Make a new stopper for the zip by carefully sewing backwards and forwards a few times over the teeth, cut off the excess then secure each side of the tape to the seam allowance using a regular zip foot.

Once the zip was in and side seams sewn up I checked the fit on myself. I cut a UK 16 and overall I’m happy with the fit and apart from the length I made no alterations to the bodice. Because I made the linen version first I already knew that the shoulders were a bit too broad for me and the sleeves dangled too much off the crown of my arm. I calculated that I needed to remove approximately 3cms to lift them up to a slightly better position. I found I didn’t need to alter the sleeve head though, fortunately it still fitted into the armhole. Another thing I did decide at this point was that the sleeve needed ’something’ else so I mocked up some small pleats and pinned the sleeve into the armhole to try out the effect.

I mocked up some small pleats with the sleeve pinned into the armhole.
I drew some markings so that I could then transfer the pleats equally to both sleeves.
More old-fashioned tailor tacks to mark the pleats.
The pleats are equally divided across the centre line of the sleeve.

After making the pleats in the sleeves and sewing up the underarm seam I used a ‘pin hem’ to finish the edge. This is similar to a simple rolled hem but even narrower. Begin by stitching a turning of approx 1cm very close to the edge, trim this carefully  

Sewing a pin hem, this is useful technique well worth mastering because if you haven’t got a rolled hem foot which could do the job, this gives a beautiful hem finish to fine or delicate fabrics.
Finished pin hem on the sleeve
Because I’d made the pattern alterations to the skirt length I wasn’t surprised to find there was a slight discrepancy in levels at the hem. Using a long ruler I averaged out a new straight line and then pin-hemmed it.

I love the 1930s/40s vibe of this dress, the drapey qualities of the fabric enhance the bias lines of the skirt in particular. I really enjoyed the challenge of putting the dress together, there are no particularly difficult techniques as such but it’s an interesting puzzle which you’ll need to spend a little time concentrating on, you’ll be rewarded with a striking but really wearable dress.

Thank you to Trend Patterns for gifting me the pattern, there was no expectation to write a review. You can read my previous review of the Square Dress pattern here. The fabric was provided by Lamazi Fabrics in return for a review which is also published on their own website.

I hope you find some tips and advice in here that might be of use to you if you’re thinking of using a fabric that needs a bit more forward planning than you’re used to. Trend have created another beautiful pattern with stunning and unusual details but the pieces cleverly work with the grain of the fabric so that working with the bias cut is a lot easier than it usually is. They have been gradually increasing their size range too so the TPC26 comes in UK sizes 6-22.

Quite a long blog this time so thank you for reading this far and, until next time,

Happy Sewing

Sue