Zippers can feel like a wild beast that can never be tamed,” says Mike Boatman, owner of Boatman Marine Canvas in Oklahoma City, Okla. “When you start working with zippers for the first time, you find out really quick that it’s not as simple as sewing the zipper onto a piece of material.”

Although Boatman has been dealing with the “wild beast” for decades, working on zippers has taught him there’s always more to learn. Part of this is because when the modern zipper was first introduced in the early 1900s, it was intended to be installed in a straight line and designed for that purpose, he explains. But since marine fabricators often encounter a lot of curves in their work, it’s a “whole new level of fun to figure out,” says Boatman.

Even relatively straightforward tasks can prove maddening.

“You can sew on one side of the zipper then sew on the other side, and you can be 1 inch off on one side compared to the other,” Boatman says. “Now the zipper doesn’t line up and because of that, your material will not lay as smooth as it should. Now you have to take the seams out of one side, and you stretch, pull and hold the mouth just right and hope the zipper will line up better on the second try.”

There is a lot to learn about zippers, agrees Mike Charlton, co-owner with wife Rachel of Charlton’s Marine Canvas in Yorktown, Va. Zippers are extremely complicated, he says, with a lot of learning taking place through trial and error. For example, one of the most common mistakes Charlton sees is installing “the box or the pin on the wrong side or the wrong direction,” something he attributes to not fully grasping how different ways of installing zippers can make them easier or harder to use—or cause them not to work properly at all.

Take fast powerboats for example.

“One of the ways people make mistakes [on these boats] is, on horizontal zippers, you want to install them starting from the front of the panel and ending in the back of the panel,” he says. “The reason for this is so the zipper will naturally stay closed. If you install the zipper in the opposite direction, the wind can push the panel and open the zipper all by itself.”

Tips, tricks and hacks

Charlton says a good way for marine fabricators to get a better handle on zippers is to join the Marine Fabricators Association (MFA), a move Boatman also recommends.

“If you are learning, you should show up at [as many of] the MFA conferences and regional workshops as possible so you can learn from the experts who have figured out all these tips and tricks,” Boatman says. “They will be willing to help you master the art of zippers.”

The main zippers Boatman relies on are the YKK^® #8 and #10 tooth. However, he uses other types, depending on the job. For example, one sailboat needed a 243-inch separating zipper, requiring him to search the internet to find the right solution. It’s not about the brand—it’s about delivering the best possible outcome for the customer, Boatman says.

He usually uses zippers with plastic teeth and metal pulls. “I’ll only use a plastic pull if it is an odd size and that is the only thing I can get it in,” he says. On boat covers, bimini tops and enclosures, he uses chain zippers, saving coil zippers for cushions when it’s a “non-separating zipper situation.”

Taking the same approach is Southern Stitch Canvas & Upholstery LLC owner and operator Steven Wayne. His Gulfport, Miss., canvas and upholstery shop services the marine, auto and commercial industries. He says that 95 percent of the time, he uses metal sliders and pull tabs. For smaller upholstery jobs, he typically uses a YKK #5 or #8, preferring coil rather than chain tooth for these projects.

For larger canvas jobs such as an enclosure, Wayne likes to use a YKK #10 coil on the U-zip roll-up windows, since coil bends better around the radius compared to chain tooth. However, he’ll use a #10 chain tooth for the joining zipper for the adjoining panels.

Although he prefers metal sliders and pull tabs since those made from plastic are likelier to break, metal does require some design adjustments. For example, when used on cushions, metal sliders and pulls have the potential to damage surrounding surfaces. Wayne addresses this concern by integrating a pocket into the cushion to prevent such contact.

Another issue is that metal sliders and their pulls, particularly those installed for exterior applications, are subject to corrosion—something boat owners need to address with proper maintenance. Additionally, metal can result in unwanted tingling or rattling, which, if there are multiple zippers, could become irritating. Wayne often gets around this by removing the metal pull tab from the slider and using a little rope as a pull instead.

Charlton does this as well, saying lanyards make a zipper “much easier to use, and customers love them.” 

Another of his favorite hacks is used when sewing a zipper to a keder welt. “Sew it in the middle of the keder tape,” Charlton advises. “This will allow you to easily tighten or loosen the zipper if your canvas ends up being too tight or too loose.”

Boatman relies on Seamstick/Hi-Tack adhesive tape, applying this double-sided tape to the zipper, sticking it to the section of the material the zipper is to be sewn on. This allows him to adjust as needed, aligning everything so he only has to sew it once.

He also recommends the Trivantage^® Seamstick Taper. This tool lets him add adhesive tape to both sides of the zipper at once. Additionally, it has attachments for #8 and #10 tooth zippers as well as #5 and #10 coil zippers.

Innovations and new solutions

One innovation Wayne appreciates is that zipper tapes are now available in different fabrics, creating a more aesthetically pleasing overall look. At the same time, he wishes manufacturers could devise a zipper tape with greater colorfastness, since these tend to fade sooner than the surrounding fabric.

SunZip^™ zippers from IDEAL Fastener Corporation may offer a solution. Headquartered in Oxford, N.C., the company is the “second largest zipper manufacturer in the world,” says Jeffrey Gut, co-president, adding that IDEAL is the “only American-owned, completely vertical zipper manufacturer.”

SunZip incorporates Sunbrella^® yarn for the zipper tape, Gut explains, with the teeth and other components constructed from marine-grade, UV-resistant Delrin (plastic). The result is a zipper that is well-positioned to withstand prolonged sun exposure, with tape that is fade-resistant, water-resistant and stain-resistant.

Another zipper that recently hit the market comes from Lenzip Manufacturing Corporation, a Rolling Meadows, Ill.-based zipper manufacturer providing custom solutions for industries including marine, automotive, RV, mattress, furniture and footwear.

One of its flagship products is the #10 molded tooth separating zipper, says general manager Rene Vargas. Used for a variety of projects, including curtains and enclosure panels, the #10 features a smooth-gliding slider over the zipper chain, resulting in fast and efficient installation, he says.

Wanting to bridge the gap between its #10 and its larger #15 and #20 options, Lenzip launched the #12 molded tooth zipper. Designed for high-stress marine applications, the #12 features a “more robust slider,” says Vargas, with options such as a “jewelry-quality, stainless steel slider,” and wider tape edges for added reinforcement during sewing.

“[It’s] particularly suitable for large yacht enclosures and sail packs on sailboats, where the sheer pressure and frequent handling can cause smaller zippers to wear down over time,” Vargas says.

Lenzip also offers coil zippers. Although Vargas says molded tooth zippers are the preferred choice for most marine applications, coil zippers provide more flexibility for curved openings. However, he adds, because their coils are sewn to the tape, “which can become the weakest point over time,” they can be at risk from prolonged sun exposure.

“Selecting the right zipper for a project is critical in marine fabrication, where conditions like sun exposure, saltwater and wear and tear can shorten the lifespan of materials,” says Vargas. “Ensuring the longevity of both zipper types requires careful consideration of the materials, proper protection and choosing the right product for the specific application.

“To make the selection process easier,” he continues, “we recommend that fabricators evaluate their project’s scale. For example, single items versus bulk production; the functional requirements of the zipper such as open or closed ends, continuous or finished; and any aesthetic or durability needs.”  

Pamela Mills-Senn is a freelance writer based in Seal Beach, Calif.

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SIDEBAR: Zipper speak

Zippers are the sum of their parts. Steven Wayne, owner/operator of Southern Stitch Canvas & Upholstery LLC in Gulfport, Miss., outlines for new fabricators that zippers are comprised of:

• A slider: This is the mechanism that opens and closes/joins the zipper. Attached to the slider is the pull tab or pull, the handle-like part that is grasped to move the slider up or down the zipper. Both slider and pull tab typically are made of metal rather than plastic, since metal tends to be hardier.
• Teeth: These can be plastic or metal, although plastic is the overwhelming preference. Metal teeth are used rarely and only in certain (typically non-marine) applications.
• Fabric tape: Running along both sides of the zipper, its edges are sewn to the surrounding material, securing the zipper.

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SIDEBAR: Trial, error, success

Sewing two dissimilar materials to one zipper “is always a challenge,” says Mike Boatman, owner of Oklahoma City-based Boatman Marine Canvas. He says lining up both sides so they end up together at the top of the zipper is difficult. As an example, he mentions one project he did for a 2005 Sea Ray^® Sundeck 240.

“We reskinned the bimini top with Charcoal Gray Sunbrella^®,” Boatman recalls. “We installed two zippers on the front edge of the bimini. Then we had to add a 12-foot sail shade to the bow of the boat using WeatherMAX 80 3D. Two totally different materials with absolutely two different stretch factors.”

It took some trial and error, he continues. They ended up adding Sunbrella binding to the edge of the WeatherMAX material, relying on hash marks and adhesive tape to place the zipper exactly where it needed to go. “The shade sail turned out great,” Boatman says.

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SIDEBAR: Zipper Resources 

(As listed in the 2025 Marine Fabricator Buyer’s Guide)

Action Upholstery Supply Inc. 
actionup.com

Alberta Tent & Awning Co. Ltd. 
albertatentandawning.ca

American Plastics 
americanplastics.com

Ideal Fastener Corp.
idealfastener.com

Innovative Industrial Solutions Inc. 
iisfla.com

J. N. Zippers & Supplies Corporation
jnzipper.com

Keyston Bros.
keystonbros.com

Lenzip Mfg. Corp. 
lenzip.com

Manart Hirsch Co. Inc. 
manart-hirsch.com

The Miami Corporation
miamicorp.com

Paskal PK Zippers & Fasteners 
paskalPK.com

The Quality Thread & Notions Company
qualitythread.com

Rex Pegg Fabrics Inc. 
rexpeggfabrics.com

Rochford Supply 
rochfordsupply.com

Sailrite^® DBA JustWholesale
justwholesale.com

Trivantage LLC 
trivantage.com

TRU^® Zip 
truzip.com

Vicar International
vicarinternational.com

YKK^® (U.S.A.) Inc. — Tape Craft Corp. 
ykkamericas.com