Hey everyone. Today you'll learn how to turn orphan test blocks and leftover batting sandwich scraps into patchwork potholders that actually earn their drawer space.
Every quilter has that pile.
Test blocks that never became a quilt.
Little sandwiches you quilted to check tension.
Pretty fabric, good stitching, no job.
Here is the good news.
A test block is already a mini quilt.
Top, batting, and backing are done.
You just need the right size.
And one honest heat check.
Most of those scraps use low-loft polyester batting.
That is thin, flat batting.
It quilts up dense and smooth.
It is perfect for a potholder shape.
It is not, by itself, a heat shield.
So we add one insulated layer.
Then that orphan block can handle hot work.
We're not reinventing the wheel here.
What You'll Need
- Orphan test blocks or quilted sandwich scraps, at least 8 x 8 inches
- One piece of insulated thermal batting per potholder, cut the same size as your block
- Cotton backing fabric, cut the same size
- Cotton binding strips, 2 1/4 inches wide
- A small fabric strip, about 1 x 4 inches, for a hanging loop
- 90/14 topstitch or denim needle
- 40-weight cotton or polyester thread
- Rotary cutter, ruler, clips, and a walking foot if you have one
How to Make It
- Sort your scraps honestly. Lay out every test block and sandwich scrap. Group them by size first, then by color. Your finished potholder wants to be about 7 to 8 inches square. Anything smaller can become a mug rug instead. No shame in that.
- Check what is inside. Peek at the raw edge of each scrap. Low-loft polyester batting sits thin and flat. That is what we want here. Thick, puffy batting makes a potholder too bulky to grab a pan safely. Save the puffy scraps for another project.
- Trim each block square. Cut your chosen block to a clean square, 8 x 8 inches is a friendly size. Keep your prettiest quilting inside the cut. This is your potholder top, already quilted. Just like that, half the work is done.
- Add the heat layer. Cut insulated thermal batting to the same 8 inches. Layer it under your block, shiny side facing the heat source, which is the pan side. Cut your cotton backing the same size and place it underneath. Now your sandwich has real heat protection.
- Quilt the new layers together. Clip around all edges. Stitch in the ditch along your block's seams, or add two diagonal lines corner to corner. Use a 3.0 mm stitch length, about 8 stitches per inch. Slow down at thick seam crossings, or the needle can snap.
- Make the hanging loop. Fold your small strip in half lengthwise, then fold the raw edges in and stitch close to both edges. Fold it into a loop. Pin it at one corner on the back, raw ends lined up with the corner edges.
- Bind it like a tiny quilt. Attach your 2 1/4 inch binding around the front, catching the loop at that corner. Miter the corners as best you can. Fold the binding to the back and stitch it down by machine or by hand. Completely up to you.
- Do the hot pan test. Set a warm, not screaming-hot, pan on it first. Hold the pan through the potholder for ten slow counts. Feel any hot spots? Add a second insulated layer next time. This test tells you the truth fast.
Tips and Variations
Make matched pairs for gifts. Two test blocks from the same fabric line make a sweet pair. Tie them with twine and a recipe card. Folks love a gift with a story. "This was almost a quilt" is a good story.
Mix sizes on purpose. An 8-inch square works for most hands. Make one bigger 10-inch square as a trivet for casserole dishes. Same steps. Just more room for hot corners.
Watch the fabric content. Use cotton tops and backings for hot work. Polyester fabric can melt at high heat. If a test block has mystery fabric, let it live as a mug rug. Keep the true potholders all cotton.
It doesn't have to be perfect. Your binding corners may pucker a little.
Mine do too.
You're your own worst critic here.
This potholder needs to grab a hot pan safely.
It does not need to win a ribbon.
Take your time. It's not a race.
If I can do this, y'all can do it.
Thanks so much for sewing along with me today.
We'll see you next time. Bye.
Shop Insul-Bright® Insulating Thermal Lining – 45" x 1 Yard at Linda's Electric Quilters.
