I added a flat zipper pouch to my #quiltcon2015lanyardswap as I reckon they’re handy to pop in cards and supplies. I don’t make these often enough so I’m writing the process down for later reference. No use reinventing the wheel every time I want to take the car for a spin! 
Ingredients:
1 zipper ( for a 6″ pouch I use an 8″ zip)
2 3.5″ x 7″ rectangle of pieced or plain outer fabric
2 3.5″ x 7″ rectangles lining fabric
2 2.5″ squares of fabric for zipper tabs
1 2.5″ x 4″ piece of fabric for split ring loop
1 split ring
Method
1. Prepare zip: fold fabric tabs in half and stitch to cover the zipper ends so that zipper + tabs extend to 7″. Trim excess zipper with strong scissors. Be careful with the metal clip!
2. Layer one outer piece, right side facing up, place prepared zipper face down lining up the top edge. Pull the zipper tab all the way to the top.
3. Top with the lining piece right side down. Pin it together. It should look like a zipper sandwich!
4. Using a zipper foot, stitch along the zipper edge keeping a nice straight seam. When you are half way down, leave the needle down and lift the presser foot. Slide the zipper pull out of the way before finishing the seam. The closer to the zipper you stitch, the less zipper colour will pop through.
5. Repeat with the second side of the zipper, layering outer fabric facing up, prepared zipper facing down and lining fabric facing down. Pin and stitch as before.
6. Open out and press outer and lining fabric away from the zipper. Topstitch either side of the zipper to keep lining out of the zipper teeth. Next you will need to stitch the bottom of the outer and lining separately forming a loop either side of the zip.
7. So, bring the long edge of the outer fabrics together RST (right sides together) above the zip and stitch using a 1/4″ seam.
8. Repeat for the lining but bring them to meet below the zip and stitch leaving a 3″ gap in the middle.
9. Open the zip to the middle! (Or you will need to do some unpicking later) Next you will need to stitch the top and bottom sides closed, attaching the split ring loop to the top.
10. Bring the zipper to the middle, aligning the outer and lining fabrics with the centre of the zip.
11. Stitch across the top, taking care to stitch slowly through the bulky seam.
12. Take the 2.5″ x 4″ piece of fabric and fold in thirds in to a skinny long piece and then in half creating a loop. Press well.
13. Insert the loop into the remaining edge, the top. Raw edges should be sticking out. Line it up with the centre of the zip. Stitch across carefully as the seam is bulky. Trim any excess fabric from the loop. Now turn it all the right way:
14. Reach through the 3″ gap in the lining and pull all the fabric through, reach through the open zipper and continue to pull the outer fabric through.
15. Poke your fingers into the corners and smooth out the lining inside. Smooth the outer and press well.
16. Using a ladder stitch or a small machine straight stitch in matching thread, close the 3″ gap. 
Give it another press and voila! Your flat zipper pouch is ready to enjoy. Or gift! PS See that cute Dollar Bill Origami Shirt? You can make one too following these instructions. I haven’t made these in years. Not much fun now that our notes are all made of plastic!
