Sewing Cast Covers

 My gymnast, who has never sustained an injury, broke her fibula at the ankle height.  Our first week after the fracture involved 2 splints and 3 casts.  When she received her first cast, she chose blue and had her friends all sign it.  The second cast could only be black and she used silver to decorate it with stars and new signatures.  The third cast could also only be black and at this point she decided to just leave it black.  The many reasons for different splints/casts were swelling, numbness relief, first cast, better cast placement, then needed to replace a cast due to shower cover (garbage bag/elastic) fail.

Once we stopped running to the doctor's every other day, I was able to look at more cast options.  We had ordered a shower cast cover to help keep the cast dry and I saw some cute covers.  The fun covers seemed to fulfill a few purposes:  give the cast personality, keep it cleaner, and give the cast a softer outside.

When I first brought up the idea of a cast cover, my daughter was not interested.  But as she put together all the events that she planned to attend along with a cast, she started to think a cast cover might be fun to have too.  Having a softer layer was an added bonus too.

We visited JoAnn's and checked out all their knits.  Many have great stretch and would fit really well over her cast.

Making a Pattern

I first traced around her cast on the side, but then decided to think of it as a sock.  I had made polar fleece socks a long time ago and knew the pattern for the sock might be a better fit.  I found some instructions online which included how to measure for the sock.  This instructable had great tips for a pattern.  I took papers and measured for the front - top to the tip of her cast, back- top to the heel, and foot - heel to where the cast ends near her toes.

My first attempt was not with her silky, stretchy new prints.  I first used an old ribbed knit I had which is stretchy, but has more bulk to it.  We got a working pattern down.  It all needed to be longer, curving in at the ankle fit better, and I decided not to finish the edges, but just tuck them over against the cast.  The silk, stretchy print hugged her cast even better and didn't bunch where the foot meets the leg.  

This fabric is temperamental as stretch knits often are.  I had the best luck using my serger first and then going over the seam with a tiny zig zag stitch.  I still left the edges unfinished and she has a 3/4"-2" extra to tuck.  I could see adding a band, but it looks better this way and it shouldn't go anywhere.  The fabric works well against her cast shoe which is a nice bonus.

Showers are going better over here too.  We start out with Glad Press and Seal over the cast, then add a fleece cuff at the top of her cast and finally slide on the commercial cast cover.  The press and seal gives the cast an easier surface for sliding on the cover and added insurance.  

Cast Cover Tutorial & Instructions

1/2 yard of fabric worked well for 2-3 covers.  My cover's greatest length is just under 18".  The actual cast length from top to toe is 14.25".  I wanted the greatest stretch along the width of the cover.

A stretch needle works well for stretch fabric.

Figure out the pattern and do a trial cover.  I made many adjustments along the way such as making the whole thing longer at both ends for folding over, narrowing the ankle area, and taking in the heel to make it fit better.  There are three pieces.  The front, the back, and the bottom.  The toe area was left with a straight edge because it is going to the edge of the cast, not creating a sock.

Determine where the bottom piece will connect and mark. 

Sew the front to the back to the marked point.

Pin or clip the bottom piece to the top and back.

Sew around the bottom making sure to close up the section where the front and back connect.  Leave toe area open.

One cover finished and inside out.

I used a serger and then reinforced the edges with a small zig zag.

The raw edges at the top and toe I decided to leave unfinished.  They tuck in and stay well because I left extra length for that purpose.  She can't really feel any of the cover, except at the top because the fabric is primarily on the cast and even the raw edges are tucked along the cast.