
Zippers are a common feature in clothing and bags, and they can be made of plastic or metal. When zippers break, it can be frustrating and embarrassing, especially if your belongings fall out. While some zippers can be fixed, others may need to be replaced entirely. This guide will teach you how to connect a plastic zipper, including the tools you will need and the steps to follow. Whether you're repairing a jacket or sewing a new dress, learning how to connect a plastic zipper can be a useful skill to have.
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What You'll Learn

Using pliers to straighten plastic zipper teeth
If the teeth of a plastic zipper are bent, this can cause the zipper to separate. In this case, you can try to straighten the teeth to fix the zipper. However, it is important to note that pliers should not be used to straighten plastic zipper teeth, as they can easily break them off. Instead, gently try to straighten the teeth with your fingers.
If the teeth of the plastic zipper are not bent, but the zipper is stuck, there are several methods you can try. Firstly, you can try to gently pull away any caught fabric from the zipper slider with your fingers, needle-nose pliers, or tweezers. You can also try lubricating the zipper teeth with a substance such as petroleum jelly, WD-40, graphite pencil lead, or soap.
If the teeth of the zipper are bent or broken, you may need to replace the zipper. However, if the teeth are only slightly bent, you can try to gently bend them back into place using pliers. Be careful not to squeeze too hard, as you could break the teeth. Additionally, if the bottom stop of the zipper (the little band of metal or plastic at the bottom of the zipper teeth) is misaligned, you can use pliers to gently pry it off and then reattach it.
If the zipper stop is plastic and cannot be reattached, you will need to create a new stop using thread. To do this, thread a sewing needle with heavy thread and tie a knot at the end. Pull the thread up through the zipper, leaving the knot on the backside of the zipper. Then, make six or seven stitches across the bottom of the zipper to create a new stop.
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Reattaching a plastic zipper slider
Once you have the correct slider, you can begin the process of reattaching it. First, unzip the zipper and locate the top stop, which is a small piece of plastic or metal that keeps the slider from coming off the top of the zipper. Use end nippers or flush cutters to remove the top stop, being careful not to cut the zipper tape. Peel away any remaining parts of the top stop from the zipper tape.
Next, slide the damaged zipper slider up and off the zipper tape. Discard the old slider responsibly. Before attaching the new slider, lightly singe any fraying zipper tape with a lighter. Then, take the new slider and start at an angle, backing it onto the zipper tape, then straighten it out. This step may require some practice and patience.
Finally, grab a replacement top stop and position it around the edge of the zipper tape directly above the top teeth, where the old stop was located. Use pliers to crimp the top stop into place, ensuring that it is snug and will not move or come off when pulled. Test the zipper to make sure it is working properly.
If your zipper is still not functioning correctly, the issue may lie with bent or damaged teeth. If the teeth are metal, you can use pliers to straighten them out. If they are plastic, gently straighten them with your fingers, as pliers could break them. Additionally, if your zipper is stuck, try using a toothbrush to remove any small particles of dirt or grime that may be causing the issue.
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Sewing a plastic zipper
Sewing a zipper is a basic skill that can be used to add a secure closure to clothing or accessories. Zippers can be made of plastic or metal, and they typically feature a slider, bottom stop, teeth, and tape. When sewing a plastic zipper, it is important to take extra care as plastic zippers are more susceptible to melting than metal zippers. Here is a step-by-step guide to sewing a plastic zipper:
Prepare the Zipper and Fabric
First, ensure that your zipper is the correct length. If it is too long, you can shorten it by sewing a new bottom stopper. To do this, mark the zipper tape where you will place the new bottom stopper, and then use a sewing machine or hand-stitch over the zipper teeth to create a strong stopper. Cut off any excess zipper tape about 1 inch (2.5 cm) below the new stopper.
Next, prepare your fabric by placing the outer fabric right-side up. Place the zipper on top of the outer fabric, right-side down, aligning the edge of the zipper tape with the edge of the outer fabric. You can use straight pins or fabric clips to secure the zipper in place. If you are sewing a curved edge, you may need to baste the zipper onto the fabric before adding the inner fabric.
Sew the Zipper
When you are ready to sew, use a zipper foot attachment on your sewing machine to stitch closely to the edge of the zipper fabric. Stitch the zipper in place, ensuring that your stitches are straight and secure. If you are hand-sewing, use a needle to stitch over the zipper teeth, inserting and exiting the needle on either side of the teeth. Go back and forth several times to create a strong hold.
Finishing Touches
Once the zipper is sewn in place, check that it slides up and down smoothly without catching. If the zipper tape is fraying, sew a zig-zag stitch around the fabric to secure the raw edges. You can also use an iron to press the tape that runs along both sides of the zipper teeth, creating a smooth finish. Be careful when ironing plastic zippers, as they can melt at high temperatures. Keep the iron moving at all times to avoid overheating.
By following these steps, you can successfully sew a plastic zipper into your desired fabric, creating a functional and secure closure.
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Replacing a plastic zipper
If your zipper is broken, you may want to consider replacing it. This is especially true if it is an invisible zipper, which is made out of thin plastic and is usually harder to fix.
Firstly, you will need to identify the type of zipper to obtain the correct replacement part. You should also ensure that the issue can be fixed with a slider replacement and doesn't require a full zipper line replacement.
Next, you will need to remove the old zipper. To do this, unzip the zipper and locate the top stop at the top of the zipper on the side with the slider. The top stop is a small piece of plastic or metal that keeps the slider from coming off the top of the zipper. Use end nippers or flush cutters to remove the top stop. Be careful not to cut the zipper tape. Once the top stop is removed, slide the damaged zipper slider up and off the zipper tape.
Now you are ready to install the new zipper. Slide the new slider onto the zipper tape, making sure that it is oriented correctly. Once the slider is in place, test zipping up the jacket to make sure it is the right type and that the issue is fixed.
Finally, grab a replacement top stop and position it around the edge of the zipper tape directly above the top teeth, where the old stop was located. Use pliers to crimp the top stop into place, checking that it securely holds the new slider in place.
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Lubricating plastic zipper teeth
Zipper-Specific Lubricants
Zipper lubricant sticks, such as the one made by GearAid, are designed specifically for lubricating plastic zippers. These products can help keep the zipper moving freely and protect against corrosion, UV damage, water, and extreme temperatures. They are also often silicone-free, which may be important as some sources suggest that silicone lubricants can be too slippery for certain applications, such as drysuits, causing the zipper to come undone.
Teflon Dry Lube
Teflon Dry Lube by PB Blaster has been recommended by some as a superior zipper lubricant that does not attract dirt. It is also safe for use with plastics. However, it may be difficult to apply this product only to the zipper when used on clothing, so it is recommended to cover the surrounding fabric during application.
Candle Wax
Applying candle wax to a plastic zipper can help improve the grip and make it easier to close. However, if the zipper is already broken, it may be better to replace it entirely.
In addition to these methods, it is important to keep the zipper teeth clean and free of debris. Using a soft toothbrush to gently brush away any dirt or sand that may have accumulated on the teeth can help maintain the zipper's functionality and extend its life.
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Frequently asked questions
To connect a plastic zipper, you will need a zipper that is longer than the fabric, outer fabric, inner fabric, a zipper foot, a sewing needle, thread, and straight pins or fabric clips. Place the outer fabric right side up, then place the zipper on top, right side down, with the edge of the zipper tape lined up with the edge of the outer fabric. Center the zipper, leaving some extra on each end. Place the inner fabric, right side down, on top of the zipper, lining up the edge with the zipper tape. Secure the three pieces with straight pins or fabric clips. Using your zipper foot, move the needle to the side closest to your zipper and sew the three layers together, getting as close to the zipper teeth as possible.
If the teeth of the zipper are bent, gently straighten them with your fingers, as pliers could break them. If the teeth are broken, you will likely need to replace the zipper. If the slider is damaged, you can try to fix it by removing it with small-tipped pliers, then reattaching it.
If your zipper won't stay up, it may be caused by misaligned teeth. Use pliers to gently bend back teeth that have dislodged or fallen out of alignment. You can also try the graphite pencil trick: rub the teeth with the lead of a No. 2 pencil to lubricate the teeth and allow the slider to move more smoothly.
If your zipper is made of thin plastic, it may be harder to fix, and you may need to replace it. If the plastic piece at the bottom of the male end has worn off, you may need to replace the entire zipper. If the zipper teeth are permanently bent or broken, you will likely need to replace the zipper.











































