Pillowcases
 

Does anybody out there have a good solution for dealing with or getting rid of that huge lump when sewing up case at the junction of the flange/cuff/case area?

Did you try hammering it before you try to sew it? Put a layer of batting over and under the offending bulky area and then put a block of wood on top and hammer it a few times. (Be sure the surface you're hammering on can take the punishment....

This works for me on bulky seams in quilt blocks.

Funny I had never noticed that bulge you mentioned so I went back to check one of my pillowcases and sure enough, there's a bit of a bulge. I tend to use the french seam method so no raw edges on the inside either. I guess you could pound it down if it bothers you that much but I mentioned, I never noticed it on mind but will from now on.

I never thought of it. Thank you.

I also use the French seam method when making my pillowcases and there may be a small bump, but never enough to really bother me. Maybe a good steam pressing and then the hammer method?

We make many kid pillowcases at church and we seldom add flange.

Pillowcases
 

I have made hundreds of the cases using the burrito method. I haven't heard one complaint yet. If the person getting the case doesn't see it all will be right in their world too.

Amen to that and thanks.