Make a Design Wall Without Duct Tape

Since my daughter was home for the fall, I moved my sewing space into our bedroom. That meant creating a new design wall. Rather than attaching it to the wall like I did in her room, I made a portable one.

quilt design wall

With the previous one I used duct tape to attach the insulation boards together and created one large design wall. I also used duct tape to attach the flannel to the back of the insulation boards.

I skipped the tape and used silk pins for this one.

And, I made three separate design walls which I hung with pants hangers. You don’t have to use yellow flannel, but this is what I had in my stash.


  • One (1) insulation board, 1/2 inch thick, 4 feet by 8 feet
  • Flannel
  • Three Flat Wood Pants Hanger


  • Measure the insulation board into thirds. Mine was 96″ so 32″ each.
  • Draw a line along each 32″ line.

measure the insulation board

  • Score the insulation board with a knife:
  • Cut with a knife or a old rotary cutter.

cut the insulation board

  • Cut the flannel.

I cut mine about 2 1/4″ larger than the insulation.

52″ by 36.5″ (it doesn’t have be this exact size)

cut the flannel

  • Wrap the flannel around the insulation board:

pin the insulation board

  • Use silk pins to hold in place. Here’s where you don’t have to use duct tape which I used in my large design wall.
  • Miter all the corners and pin at an angle so that the pin doesn’t go through the front.

miter the corners

  • Attach cup hooks to the hall.

I used chalk to mark the level line.

cup hooks

  • Attach Pants Hanger to the insulation board and hang it:

attach pants hanger

I only hung two of the insulation boards and put the other one in the closet.

This was the perfect solution for me,


Design Wall.

The Design Wall is now up!


I first taped the two insulation boards together. I used duct tape:


I ironed and pressed the flannel (no photo of that). I then pinned the flannel to the insulation boards using silk pins:


I also used duct tape to hold the corners on the back (no photo).

We — a two-person job here — installed the design board to the wall, using screws. We made sure to install the screws where the studs were located. We are not home improvement experts by any means. We had some trouble at first because the screw caught the fabric, twisting it as it went into the insulation board. We made it work in the end.


Another shot of the finished project:


Again, thanks to Sew Katie Did for the inspiration.

In search of flannel . . . for design wall

In the middle of making the Aerial quilt, I had an idea — look on to view other people’s design walls.

The blog, Sew Katie Did, had a nice design wall made from flannel:


In that post, she had a link to Garnet Hill for buying a flat flannel sheet for covering the insulation boards. Well, the sheets weren’t on sale at that time. The search began — the Container Store, L.L. Bean, Bed, Bath & Beyond, but no luck. I found 108″ flannel, made by A E Nathan, on but “zero” yards were available.

In the meantime, my husband and I found the insulation boards at Lowes:


Each piece is 1/2 inch thick by 4 feet by 8 feet (total 96″ by 96″). They cost $10.43 each. We also purchased screws and washers. (total cost $31.31). I need 3 yards of 108″ fabric to cover the boards.

I checked back a week later at and now it’s available. I ordered it immediately ($10.18 per yard at 3 yards equaled $30.54) and added some red fabric to get the free shipping for buying $35. When it’s all put together, I’ll post some photos.