How to Install a No-Leak Curved Zipper in a Vinyl Window
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- Intro - 0:00 min.
- Cutting & Marking Clear Vinyl Window Material - 1:28 min.
- Basting & Sewing Inside Half of Zipper - 7:03 min.
- Basting & Sewing Outside Half of Zipper - 13:18 min.
- Applying Binding on Zipper Half - 19:34 min.
- Basting, Binding & Patterning Zipper Flange - 25:14 min.
- Assembling & Sewing Zipper Flange - 31:32 min.
- Basting & Sewing Zipper Flange & Binding - 39:28 min.
- Cutting Slit in Clear Vinyl Window - 45:33 min.
- Adding Zipper Sliders - 47:35 min.
- Discussion of Facings & Zippers - 50:10 min.
- Tools & Materials List - 51:39 min.
- Strataglass™ 30 Gauge Vinyl Window Material 54" x 110" Clear #791123
- YKK® #10 Black Continuous Zipper Chain (Coil Chain) #102215
- Seamstick 1/4" Basting Tape for Canvas & Upholstery (50 yds.) #104167
- Thread Tex 90 Polyester or Lifetime PTFE Thread from Sailrite®
- YKK® #10 Black Double Non-Locking Metal Zipper Pull (Coil Chain) #103071
- Sunbrella® Acrylic Bias Binding Tape Black 3/4" #29138
- Seamstick 3/8" Basting Tape for Canvas (50 yds.) #129
- Dura-Skrim® Patterning Material 74" #103134
- Sunbrella® Marine Grade 4608-0000 Black 46" Fabric #4608-0000
- Scribe-All® Black Marking Pencil for Vinyl #121977
- Professional Stainless Steel 10" Scissors #123615
- Sailrite® Clear Acrylic Ruler 6" x 24" #102400
- 3M™ Specialty Adhesive Remover 32 oz. (Quart) #108984
- Protect-It™ Gray 63" Fabric #122679
- Sailrite® Ultrafeed® LSZ Walking Foot Sewing Machine #311602
- Sailrite® Ultrafeed® Industrial Sewing Table #120934
- Scribe-All® Water Soluble White Marking Pencil #120681
- Deluxe 5-1/2" Magnetic Sewing Guide #103597
- Seam Ripper Deluxe #18104
- T-Square, Marker, Tape Measure, Iron
We get a lot of questions asking how to solve the issue of curved zippers leaking water into their enclosures. Our design solves this issue in a clever way and produces a sleek, professional-looking roll-up window. Let's dive in!
Sewing a curved zipper into a clear vinyl window in a marine enclosure is not a difficult project, but how do you waterproof the zipper? Well, we had no immediate answer for this common question. So we went to the drawing board! After six prototypes, our DIY video team figured out a great solution for leaky marine curved zippers. In fact, we’re so proud of our design that we named it — The Fully Dressed Curved Zipper in a Vinyl Window.
The trick to a water-resistant curved zipper (commonly known in the marine world as a smiley window), is adding a protective double layer of a water-resistant marine canvas over the zipper plaque. In our video, we used Sunbrella® Marine Grade. This curved flap is sewn to the outside of the window and keeps water from reaching your zipper. The curved fabric barrier also lies flat for a beautiful, pleasing look. That’s why we call our design “Fully Dressed.”
When sewing window material, it's very important to check your tension since the needle will leave permanent holes in your window. Before starting your project, we recommend checking your tension with some scrap window material and binding.
Bonus: An Easier Smiley Faced Zipper Method
Watch the video below if you want a simpler way to install a U-shaped zipper in window vinyl. This simpler technique was demonstrated at the 2025 MFA Conference by Keith Purves for Trivantage. It's the easiest way to sew in a curved zipper that also includes a rain flap
Please Note: The main video at the top of this blog is still our preferred method as it is a fully dressed window and includes finishing material on the inside. But the video below is a quick, simple method that is also a valid approach.
Thanks for watching! We hope these videos taught you some new tricks for sewing a curved zipper in a marine window enclosure. What did you think of this DIY? Share your thoughts in the comments below!