Choose material for your passport cover that is thick enough to withstand normal wear from traveling. Material similar in thickness to leather works well. If you plan on making several covers to decorate the passport for different trips, you may use a lighter fabric such as sturdy cotton or linen for this temporary use.
If you plan on making the passport cover for a specific trip, choose material printed with a design referencing your location. You may choose to incorporate material to match the flag colors of the country you will visit, or you can select a print that illustrates the purpose of your trip.
You will need enough fabric to cover the front and back as well as to allow for extra space to sew. Cut out a rectangle 7 1/2-by-10 1/2 inches. Cut out four right triangles with the longest side measuring 1 1/2 inch and the shorter two sides measuring 1 inch long.
Fold down the extra quarter inch on all sides of the rectangle and hem. Fold and hem the hypotenuse of each triangle. Fold the material so a quarter inch of the patterned side lays over the wrong of the fabric. In this way, when the cover is attached, you will see a smooth hem along the sides and not the folded material. Depending on the thickness of your fabric, you may want to use a sewing machine. Place the rectangle piece facing pattern side up. Arrange the triangles wrong side up and flush with each corner of the rectangle, so the right angle of the triangle lays over the right angle of the rectangle. Sew triangles in place. Turn the triangles inside-out so the seams will remain hidden inside.
The triangles will serve as small pockets to keep your passport covered. When you fold the passport closed, the cover will fold with the passport, much like a book cover. Tuck the corners of the passport into the sewn-on triangles and close.
