Ultralight Wind Shell

Breathable weather shell for fastpacking and trail running

Intimidated by apparel? Want a minimalist super ultra light shell without spending a fortune?
Our UL Wind Shell sewing pattern is the perfect entry point into making your first technical garment.


Beta Series Apparel Pattern

  • Modern wind shell sewing pattern with optional zippered hand pockets
  • High collar and tight fitting hood that won't blow off in wind
  • Raglan style sleeves with no seam on top of shoulder
  • Men's sizing with small, medium, and large options included
  • Highly packable and as UL as they come... less than 3 ounces!
  • Pattern is easy to customize for features or fit

Body Measurements and Fit Guide

The UL Wind Shell is designed to be part of a layering system. Generous ease is provided for breathability and movement over form-fitted active insulation layers.

Body Measurement (inches) Small Medium Large
Chest 34-36 37-40 41-44
Hips 35-37 38-40 41-44
Sleeve 32-34 33-35 34-36


Beta Series patterns are tested and complete sewing patterns, available to the community to gauge interest and gather feedback. They are provided with basic instructions yet limited variations. Depending on popularity, a full video sewalong may or may not be created. While a beginner can make this project, it shouldn't be your first sewing project. Grading between sizes may be required for perfect fit.

Downloadable PDF sewing pattern includes

  • Print at home pattern suitable for both Letter and A4 sized paper
  • Large format pattern for 48" roll feed or A0 sized paper
  • Seam allowance instructions and basic construction order of operations
  • Men's/unisex small, medium, and large sizes

Valid email address required for download link and revisions for this specific pattern.


A sampling of fabrics are listed to spark your imagination. Bold fabrics were used in my build.

Fabric Panel Options Length (Width)
Shell 1.0oz HyperD uncal, 20D ripstop nylon uncal, 0.66 oz Membrane 10 2 yd (58-60")
Bias Binding Recommend same fabric as shell, bias tape, or serger 0.5 yd (58-60")
Main Zipper Designed for YKK #3. Waterproof zipper, Coil jacket zipper >= 30 inches

Learn more about technical fabrics, recommendations, and trusted suppliers in our Fabrics Guide