DIY: How to Patch a Down Jacket at Home

Here at Burton, we’re a big fan of sustainability and we believe that prolonging the useful life of gear to avoid buying new is better in a lot of ways. So, if you find that your otherwise healthy down jacket has a hole, don’t replace it, patch it! The following step-by-step guide will walk you through the exact steps that our warranty repair team uses so you can patch that down jacket right at home.

But first, a quick reminder: Most Burton outerwear is covered with a limited lifetime warranty that is active for as long as you own the gear and use it for its intended purpose. Burst a seam while riding? That may be covered under warranty. Got ripped up from playing with your pet chinchilla? Probably not covered under warranty. But that's exactly why we put this guide together, you chinchilla-loving snowboarder.

To initiate a warranty claim, please visit the warranty center.

The Benefits of Patching a Down Jacket at Home

If warranty isn’t an option or you just prefer to tackle a down jacket patch yourself, there are a few key benefits that you may not have considered.

1. DIY reduces your carbon footprint: Taking on this project at home will eliminate two (potentially) long-haul shipments: you sending the jacket to Burton and Burton sending the jacket back to you.
2. Repairing gear reduces your overall consumption: We make gear to last and you should only get brand new when you need to. One exterior hole in the fabric should not relegate a jacket to the landfill.
3. Completing this task at home will get you back on the mountain faster: Once we receive your item, we guarantee that it will be assessed within 48 hours to determine if the repair will be covered under warranty. However, once assessed the item will be added to the back of the repair queue and will typically be completed in 3-4 weeks (and up to 8 weeks during peak winter season), whereas a competent DIYer can knock out a down jacket patch at home in under a few hours.
4. Repair work creates a sense of pride: People who perform this project at home report feeling a sense of personal accomplishment.

How to Patch a Down Jacket at Home: Step-by-Step Instructions for Applying Self-adhesive & Sewn Patches

While it may seem daunting to operate on your expensive outerwear, we promise that it’s much easier than it looks. Plus, it’s important to get down items repaired as quickly as possible to prevent any of the down feathers from coming out. After all, that’s the part that keeps you warm.

1. Clean the Area that Needs to be Patched
2. Remove any Loose Feathers
3. Apply Self-adhesive Patch
4. Optional: Measure and Cut Technical Fabric Patch
5. Optional: Sew the Fabric Patch onto the Jacket

Step 1: Clean the Area that Needs to be Patched

Using isopropyl alcohol and a clean cotton rag, lightly dab around the entire area to make sure it is completely free of dirt. Allow the area to dry completely.

Step 2: Remove any Loose Feathers

Wrap a piece of masking tape (sticky side out) around your fingers and gently tap the torn area to remove any loose down feathers and give yourself a clean workspace. Alternatively, a pair of tweezers can be used to coax any loose down back into the jacket.

Step 3: Apply Self-adhesive Patch

Select a reliable self-adhesive outerwear repair patch (we like NoSo) and carefully cut out a piece to cover the hole. Note that the patch should be larger than the hole in the jacket by at least 1/2 inch (1 centimeter) on all sides. Double-check the size and positioning of the patch before removing the backing and then press it onto the hole with even pressure, working outward from the middle to eliminate air bubbles. Apply gentle heat to set the patch.

Pro tip: Save the rest of the patch for future use.

Step 4 (optional): Measure and Cut an Outer Layer of Technical Fabric

For a more finished appearance, you can sew a piece of technical fabric over the self-adhering patch you just used. You can generally find lightweight, nylon, or polyester ripstop at most fabric stores, and specialty retailers online should offer swatches of waterproof of fabrics like GORE-TEX. Measure out an area that covers the entire patched section of the jacket. Note that the fabric should be larger than the initial patch by at least 1 inch (2.5 centimeters) on all sides. Line up the fabric where it should go, turn under each side of the patch about 3/8 inch (1 centimeter) to strengthen the sewing area, and pin it into place.

Pro tip: Try to align the patch with the quilt pattern stitchlines on the jacket, when possible. This approach prevents down from leaking out of the new stitchlines that are created and generally makes for a better looking repair.

At this point, your jacket should look like a voodoo doll of a jacket that you don’t really like very much.

Step 5 (optional): Sew the Fabric onto the Jacket

If you have access to a sewing machine, we recommend a straight stitch; if you are sewing by hand, we recommend a running backstitch. Once the fabric is secure, remove all the pins and you’re all set.

Pro tip: Patching a jacket for a child (or a child-at-heart)? Instead of a boring black square, use a cool or interesting patch to add a little flair and personal touch (think dinosaurs, cartoon characters, and super heroes).

Professional Repairs

If you’re not up for this project and your gear is out of warranty, we may still be able to assist you in getting back out on the mountain. Please reach out to the Burton Guides to chat about what your repair options might be.