The DIY Tent Design Process

Everything I’ve shared so far is based on personal opinion and should not be taken as gospel. Now, let's move on to something much more interesting—the DIY tent design process.

I have many friends who are into DIY projects, though most of them are not related to tents. The common reason behind these DIY projects is to fulfill a personal need. Many of us share the same experience: we see designs on the market that don’t quite meet our expectations or the prices are too high for us to afford. Yes, it’s true—it’s about that "personal stash" of money!

Step 1: Collecting Materials (For a Tent)

The materials used in tents are varied and include:

  • Main fabric: 7D / 10D / 15D / 20D / 30D / 40D / 70D / 210D… mainly nylon
  • Mesh fabric: 10D / 15D / 20D… polyester or nylon
  • Aluminum poles: 7.9mm / 8.6mm / 9.0mm / 11mm / 13mm… and also carbon fiber poles
  • Hardware: WJ / UTX / ITW / YNS

These are just a few examples. Let’s take a simple case for precise description: DIY’ing a pyramid tent based on the HillZero Rheum Nobile 4-6 (https://www.hillzerogear.com/).

Firstly, we should prepare 30D nylon fabric. The amount needed depends on the size of the tent, and we should prepare enough for two sets. This tent requires 22 yards of fabric, so we need to buy 44 yards. Since the first model is often a failure, I always prepare a backup fabric set.

Next, we gather other essentials like hardware, sewing thread, YKK zippers, and aluminum poles.

Step 2: Rough Size Calculations

As mentioned earlier, “All tents are based on basic size calculations. As long as the calculations are accurate, it can be done excellently.”

Tent design can be imagined like building a house. We start with the known dimensions of the tent base (depending on the size of the tent you want to create). For example: Diameter 420cm (165 inches), Height 240cm (94 inches).

We calculate the ridge length of the sides. Whether you use a computer drawing program or do it manually, you can easily determine the measurements. Since it's a regular decagon, each panel is identical.

Step 3: Creating the Model (1:20 Scale)

In this stage, we add elements like zippers, ventilation windows, and guy-line attachment points to the model. The model allows for a visual representation of the tent’s overall structure.

Step 4: Preparing Cardboard for Fabric Cutting

Once the model’s details and measurements are correct, we can create a full-scale pattern. Some may wonder why we need to make this pattern—it's to ensure accurate dimensions for cutting the fabric. Tent fabric is large, and it’s impossible to mark directly on the material. We need to prevent size discrepancies since even a 1cm error can drastically affect the final result.

A few things to note:

1.  Sewing allowances must be added. High-quality tents use double stitching, so we add 2cm extra for seams in the pattern.

2.  Straight lines aren’t always straight. Fabric is soft, and tension can cause warping in the middle, so we need to account for this and adjust accordingly.

3.  Fabric classification is crucial. Despite being a decagon pyramid tent, each piece is different due to factors like fabric width and optimal fabric usage.

4.  Fabric grain matters. Straight grain has no stretch, while diagonal grain has elasticity. This affects how we lay out the pieces to avoid future issues.

Step 5: Sewing and Assembly

Typically, small parts like windows, zippers, and reinforcement patches are sewn first. Then, we move on to assembling the larger body of the tent, piece by piece.

Sewing may sound simple, but it’s an art. If you’re unfamiliar with sewing machines, it can be quite a headache.

Achieving high-quality stitching requires skillful hands, and this task is not for beginners. However, DIY enthusiasts can certainly give it a try, and even if it’s imperfect, it’s your very own creation—something you can proudly use.

Final Thoughts

DIY tent-making is an incredibly fun and creative hobby that adds energy to your spare time. Each step of the process has its unique challenges, but with patience and persistence, you’ll learn to solve them. Remember, advice from others is helpful, but only through your own effort and understanding can you overcome these challenges.

Thank you for reading! I’ll continue to share more tent-making processes in the future. The pyramid tent is just a beginner’s project, but to make it truly precise requires meticulous work. If you have any questions, feel free to email me at: nicksan@hillzerogear.com. I’ll do my best to respond! 

Location: Shenzhen, Guangdong Province, China

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