I think by now I have made thousands of these neck coolers, but I do it differently because my group and I found the following process much faster and no turning a skinny tube!
I take 44" fabric and cut it into 4" strips. Then with wrong side down, I turn the long sides down about 1/2 inch and press. I then fold in half, wrong sides, together, and sew the short ends of the strip and cut off the excess. Turn the open tube, right sides out and press, matching turned under edges. Find the center (I fold to find it) and stick a pin in it and measure 4" away on both sides from the center and then again 8" away from the center on both side and stick a pin to mark location of pockets.
At the sewing machine, I then create the pockets by sewing the five spots where my pins are located (remember, you are sewing on the right side of the fabric and folded long edge is tucked in). I always backstitch or double stitch for strenght because those little crystals can escape easily.
Next, I start topstiching from one end to close the tube until I get to the first pocket. Then I carefully put the crystals in the pocket and continue to topstitch it shut, doing the rest of the strip the same way. I use a very, very short stitch length.
We have also learned that a scant 1/4 tsp of crystals is best because it makes the neck cooler much more flexible when wet. A full 1/4 tsp really overfills the pocket almost to the point of bursting. We have been using "Moisture Plus" water crystals, found at WMart.
Fabric should match as closely as possible to uniform colors so a small all over random print is best. I found a fabric at WMart that was ivory with tiny splashes of light brown and muted green that was perfect. I visited about 10 stores and purchased all I could find and have about 40 yards left out of about 100.
When my son was in Iraq, the neck coolers were very popular and so was he because I sent about six dozen weekly. He is heading back there at the end of August, so I am frantically sewing again!
If anyone wants to make neck coolers for soldiers, but does not know where to send them, you can contact me or go to www.anysoldier.com and read the requests from the soldiers in the Middle East. They don't need to request the neck coolers, just knowing they are in the hot desert is enough reason to send them.
Sharon and others that make these neck coolers, may I thank you for your kindness and consideration of our troops. It's the little bits of comfort from home, such as neck coolers, that can make a world of difference to a deployed soldier.
Diane
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