[Update August 2014: I have another version of this zipper card pouch, they look about the same from the outside, but it is more spacious inside as I have hidden the seam allowance.]
Zipper Card Pouch
To make: 1
Pouch Body [5 1/4″ x 3 3/4″]
1. Fabric – Canvas Stripe, 2
2. Fabric – cotton polka-dots, 2
Side Gusset [1 3/4″ x 2 3/4″]
3. Fabric – Canvas Stripe, 1
4. Fabric – cotton polka-dots, 1
Divider [5 1/2″]
5. Twill tape – 1″, 1
6. Grosgrain ribbon – 3/8″, 1
7. Zipper – 7″ (click here to watch how to shorten metal zipper)
8. Twill tape for biding – 10″
1. Sewing machine, with normal foot and zipper foot
2. Sewing kits
3. Pencil or Erasable fabric marker
6. Tools for turning like awl and knitting needle or bamboo turner
Finished Dimension: 4 1/2″ (W) x 3″ (H)
Seam Allowance: 3/8″
Note: If you are not using canvas but slightly thinner material like quilter weight cotton, you will need to attach an interfacing or stabilizer to make up the thickness and steadiness.
Materials and Dimensions
Get ready the materials with the correct dimension respectively.
Left: Sew ribbon to the center of the twill tape to make a divider in the card pouch.
Right: Mark 7″ zipper according to the measurement of 0, 1/4″, 3″ and 7 1/2″.
Remark: offset the measurement 1/4″ from the zipper stop as shown in the photo.
1. Place canvas and polka-dot right side facing each other. Sew top and bottom.
2. Turn to right side. Top stitch near the top and bottom edges.
3. Fold the gusset into half (vertical), sew near the fold but make sure it sews the canvas too.
4. A sewn crease line created along the center of the gusset.
Place and pin the divider 1″ below the top seam allowance. Sew the divider to the lining a little outside the seam line (onto the seam allowance).
1. Sew the gusset 1/2″ below to the top seam lines. Attach both sides.
2. Right side of the lining with gusset attached.
Change to zipper foot. Pin and sew zipper (wrong side facing up) to the canvas, just outside the seam line, sew to the 3″ point  at the zipper, don’t go beyond. For advanced and experienced sewer, pining will do (same to the rest of the similar steps).
Fold  over then flip the lining , align to the zipper and canvas. Pin. [Better explanation from Grandma G: Fold (following arrow #2 in diagram) piece A over piece B so right sides are together. Then flip the entire lining (following arrow, #3) toward yourself and place over zipper and canvas. Pin.]
Sew on the seam line, stop at the 3″ point on the zipper too.
You will see this arrangement after folding the lining to the back of the canvas.
Repeat the sewing of canvas and lining to another side of the zipper.
Bend the zipper, pin to the canvas. Fold the end of the zipper onto the seam allowance.
Sew them together just outside the seam line.
Now bring the lining to the front with right side facing the canvas, align, pin and sew it to zipper and canvas on the seam line.
Top stitch near the seam lines on the canvas along the L-shaped zipper.
Repeat the sewing steps to the other side. Adjust the zippers by pulling up and down if required so that the zipper don’t get in the way of your zipper foot during sewing.
Fold the pouch with right side facing each other. Pin and sew the side and bottom of the pouch.
If you are using stripe canvas or any print that needs to align, check if they are aligned properly at the seam line.
Clip the corners.
Pin the twill tape to the seam allowance with 1/2″ access at the end.
Fold the tape nicely at the corner.
Fold the tape end down to the other side, pin. Repeat the same to the other end.
Fold the tape and pin to the other side of the seam allowance. A help from an awl will be good to achieve a neater fold at the ends and corner.
Sew the twill tape binder on the seam allowance.
If you find that the seams are too bulky and thick. Using of warm iron can be hard to press them down.
I am not sure if this is a good / normal method… I use a hammer to flatten it.
Lightly pound the seam allowance of the lining side of the pouch before turning them in. Use a piece of folded fabric / cotton flannel to protect the pouch to prevent pound marks. Be careful when pounding at the corners where the zipper meets, don’t accidentally spoil zipper teeth, pull and stops.
Turn the pouch right side out, adjust all corners and bound seam allowance. Lightly pound to flatten the bulging seams from outside.
A completed canvas zipper card pouch with a side gusset that can easily hold up to 20 – 30 credit cards, discount cards and/or member cards.