Sett Solutions and Binding a Denim Rag Rug

After correcting the two threading errors on my second warp on the Weaver's Delight, I planned on weaving a denim rug next.

The loom was warped at 12 epi and set up to weave plain weave.  That was no problem at all with the rug at the left.  The fabric used for the weft was a polyester double-knit, so I didn't have any problems with the weft packing in tightly.

It took several attempts with the denim to get an acceptable rug.  Twelve ends per inch would not work with denim, or at least not with the plain weave I was attempting.  I had done a sample before on the tail end of a previous warp with strips cut 3/4" wide. It worked out great, so I wasn't anticipating problems. 

I could not get the denim to pack in tightly.  Then I remembered that my sample was set at 12 ends per inch, but it was a twill variation (Chicken Tracks), which essentially changes the ends per inch on each pick to six instead of twelve.  That allowed a nice tight weave.

Rather than re-thread, I changed the cams on the loom to the twill set-up.  It is just a simple 2-2 twill, and it made all the difference to how the denim packs down.  The 3/4" wide strips were just right.  An alternative could have been woven with plain weave with doubled ends set at six ends per inch.  I wouldn't attempt a rug with regular rug warp at only 6 epi.  It needs to be doubled to be strong enough for a sturdy rug.

Because I started over so many times before getting something that I liked, I neglected to start over again to give a proper header for a hem at the beginning.  To solve that problem, I looked in my Rag Rug Handbook for instructions for binding a rug.

I tied off my warp before removing it from the loom.  This photo is the start of the rug.  If I had been thinking ahead, I would have just glued the header and let it dry, thus avoiding the need for all the knots.  That is what I did at the end of the rug.

On the cutting table, I trimmed the warp close to the knots.

I used denim for the binding at both ends of the rug.  I wanted the binding to be about 1" wide when finished, so I cut two strips about 3 3/4" wide and a little longer than the width of the rug.

With the right side of the binding against the rug and even with the edge, I stitch through the two layers at the first denim pick.

This is not a project for an ordinary home sewing machine.  I am using my industrial upholstery machine.

Fold the hem ends as shown in the photo and stitch the ends even with the edge of the rug.

I didn't like how the hard warp knots felt under my feet, so I put some glue on the header, let it dry, and then cut through the knots to remove them. 

The hem ends were trimmed to reduce the bulk and then turned right side out.

The hem is turned up to the first line of stitching and then top-stitched.  I am sewing through four layers of denim on the main part of the binding plus the rug, and on the ends, eight layers of denim.

I don't think this would be my first choice for a hem, but I was glad I had the option.

I wish I had taken a better photo of the finished rug, but it's gone now, with no chance for a do-over. I gave it to our daughter Carolyn and her husband Eric for a Christmas gift.  The finished size is approximately 30" x 50".