Hi all! Long time lurker, first time poster 
I just finished a Supergirl build for a friend of mine and thought I would share some WIP photos and build details as I haven't seen many around.

FABRIC:
- Screen printed stretch (My friend purchased it from In Disguise Designs). I think she purchased 5 tiles of the blue and red + the tile with the chest logo. They come in 50cm x 70cm tiles. Print quality is amazing and it stretches well with the fabric. The only downside with it was that it had a sticky residue (almost like a glue? I'm assuming it's from the treatment process) on the back of the fabric which made it difficult to sew with at times and left my hands feeling kind of gross after handling it for a while. You definitely need to pre-wash it (cold gentle machine wash) which managed to remove most of it, but there were still patches which would stick to my machine feet... :/
- non-stretch pleather for the cape (approx. 1.2m @ 150cm wide) + cotton lining (1m)
- belt was provided
I relied on a lot of the promotional images for most of the build as well as a BTS video of the wardrobe tour on YT, and eventually screencaps (more on that below).
------------------------------
BUILD
Leotard:


I started off with a basic dance leotard pattern with a skirt from Kwik Sew. I made a toile out of lycra and drew in the panels on the front side, as well as the sleeve seams and altered the neckline. The pattern doesn't have a zip or any sort of closure, so I split the back piece in half and added an invisible zip. I left out the skirt on the pattern, and modified the crotch to make it a flap (for easy bathroom visits!). Early on, we weren't sure whether to sew the skirt into the leotard, or keep it separate. We ended up keeping it separate. I used an overlocker, but you can also use a zig-zag stitch or stretch stitch if you don't have an overlocker/serger.
The neckline has a red facing which peeks over the edge.
------------------------------------
Sleeves:

I struggled for a long time with how to do the sleeves with the top stitch detailing. It then occurred to me that the sleeve would have to have 2 vertical seams - one running down the top/outside of the arm, and another running down the underside. I had been trying to do it with 1 vertical seam. Essentially, the sleeve is made up of 4 pattern pieces.

The top stitching was another challenge. I rarely use use stretch fabrics. I prefer my wovens. I've always been told never to use straight stitch on stretch fabric because it doesn't stretch and I didn't want stitches to snap, but I asked a friend of mine who makes a lot of dance wear and she mentioned lowering the thread tension.
I increased the stitch length and lowered tension. Normal tension on my machine is 5.5. I lowered it to about 4, which was also buttonhole tension. It may differ for your own machine, so best to test it!

<< test
For the thumbhole, I lengthened the sleeve cuff, shaped it and cut a small circle approximately where my thumb was. The way I originally made it, I found it gaped in the area between thumb and fingers so I cut the excess and added another seam which worked perfectly. The edges were folded over by a couple of mm and zig-zag stitched.

I just finished a Supergirl build for a friend of mine and thought I would share some WIP photos and build details as I haven't seen many around.

FABRIC:
- Screen printed stretch (My friend purchased it from In Disguise Designs). I think she purchased 5 tiles of the blue and red + the tile with the chest logo. They come in 50cm x 70cm tiles. Print quality is amazing and it stretches well with the fabric. The only downside with it was that it had a sticky residue (almost like a glue? I'm assuming it's from the treatment process) on the back of the fabric which made it difficult to sew with at times and left my hands feeling kind of gross after handling it for a while. You definitely need to pre-wash it (cold gentle machine wash) which managed to remove most of it, but there were still patches which would stick to my machine feet... :/
- non-stretch pleather for the cape (approx. 1.2m @ 150cm wide) + cotton lining (1m)
- belt was provided
I relied on a lot of the promotional images for most of the build as well as a BTS video of the wardrobe tour on YT, and eventually screencaps (more on that below).
------------------------------
BUILD
Leotard:


I started off with a basic dance leotard pattern with a skirt from Kwik Sew. I made a toile out of lycra and drew in the panels on the front side, as well as the sleeve seams and altered the neckline. The pattern doesn't have a zip or any sort of closure, so I split the back piece in half and added an invisible zip. I left out the skirt on the pattern, and modified the crotch to make it a flap (for easy bathroom visits!). Early on, we weren't sure whether to sew the skirt into the leotard, or keep it separate. We ended up keeping it separate. I used an overlocker, but you can also use a zig-zag stitch or stretch stitch if you don't have an overlocker/serger.
The neckline has a red facing which peeks over the edge.
------------------------------------
Sleeves:


I struggled for a long time with how to do the sleeves with the top stitch detailing. It then occurred to me that the sleeve would have to have 2 vertical seams - one running down the top/outside of the arm, and another running down the underside. I had been trying to do it with 1 vertical seam. Essentially, the sleeve is made up of 4 pattern pieces.




The top stitching was another challenge. I rarely use use stretch fabrics. I prefer my wovens. I've always been told never to use straight stitch on stretch fabric because it doesn't stretch and I didn't want stitches to snap, but I asked a friend of mine who makes a lot of dance wear and she mentioned lowering the thread tension.
I increased the stitch length and lowered tension. Normal tension on my machine is 5.5. I lowered it to about 4, which was also buttonhole tension. It may differ for your own machine, so best to test it!



For the thumbhole, I lengthened the sleeve cuff, shaped it and cut a small circle approximately where my thumb was. The way I originally made it, I found it gaped in the area between thumb and fingers so I cut the excess and added another seam which worked perfectly. The edges were folded over by a couple of mm and zig-zag stitched.



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