How to Fix Zippers on Outdoor Gear
Fixing Zippers is Easier Than You Think!
Some zipper issues can be fixed with a pair of needle nose pliers. Photo by Brandon Lampley.
January 26, 2024
Home > Learn Skills > Cleaning, Repair and Maintenance
A finicky or broken zipper doesn’t have to lead to endless frustration.
Depending on the issue, some zippers can be fixed in a pinch with nothing more than a pair of needle nose pliers. A bit of cleaning and lubrication will often smooth the operation.
Whether you have an issue with your backpack, tent zipper, or rain jacket, or sleeping bag, zipper repair is an easy outdoor gear maintenance skill that can help you extend the life of expensive outdoor gear.
Read More: How to Repair a Tent
Related: How to choose Used Gear
Zippers separate and the zipper slider won’t close. If you are unable to realign the zipper by taking it apart as described in Part 1, you may need to replace the zipper slider. Photo by Brandon Lampley.
Part 1: Simple zipper fixes
Sometimes zippers act up for minor reasons, like catching on dirt or debris caught in the teeth. If this is the case, simply inspect the whole zipper for anything that might be caught. Clean out the stuck zipper as best as possible before trying to zip up again.
Cleaning your zipper after a particularly dirty excursion with a solution specifically made for this purpose can help prevent zipper jams. Reluctant zippers often benefit from a bit of lubrication.
If you're in the field, chapstick or a bit of beeswax from a candle can work in a pinch—just be careful not to let sand or grit stick to it. Like most field repairs, we recommend touching it up when you get home, in this case, by using a cleanser formulated for zippers.
If the zipper pull tab slides but leaves the teeth unzipped, your issue is likely with the slider and not the zipper teeth. Check the slider to see if it has widened or loosened. For a quick fix, you can use needle nose pliers to gently compress and tighten the broken zipper slider. This may help the slider to engage with the teeth again and allow things to zip up nicely. It’s an easy enough fix to do in or out of the field.
Use a pair of needle nose pliers to slide broken sliders off teeth. Photo by Brandon Lampley.
Part 2: How to Replace a zipper slider
If your zipper slider has worn out completely, you can replace it yourself without having to take your jacket or outdoor gear to a professional.
You’ll need a few tools to fix a zipper:
a new zipper slider
a new zipper stopper.
Luckily, most of these items come as part of a zipper repair kit, so you don’t need to source them individually.
A zipper repair kit includes:
a seam ripper
two large needles
thread
10 top stops
3 slider coil zips (#3, #5, #10)
2 slider coils double (#5, #8)
1 slider Vislon® Single (#5).
The numbers refer to the size/model of the zipper.
Step 1: Identify the zipper type
Not just any new zipper slider will do for your repair. You’ll need to look carefully at the back of your troublesome zipper slider to find the model number and get a matching one. Using this information, you should be able to purchase a matching one online.
If you are not able to find the exact model to match your zipper, the repair likely won’t work. For example, most jacket zipper sliders use a smaller model than tent zipper sliders, so cannot be used interchangeably. If you are unable to locate the correct model and size, you’ll need to have the zipper professionally repaired.
Step 2: Remove the zipper slider
If you’ve found the right replacement for your zipper slider, you’ll need to remove the old one. In order to do this, use needle-nose pliers to remove the plastic or metal zipper stopper at the end of the zipper, then slide the broken slider off the teeth.
Step 3: Put the new slider on
Gently slip the new zipper slider onto the zipper teeth from the bottom.
Step 4: Replace the zipper stopper
Place the stopper into the slots at the end of the zipper and gently pinch it into place with needle-nose pliers.
Read More: Eco-Friendly Gear Swaps to Reduce Your Environmental Impact
Jackets with assorted zipper issues. Even if you have to pay a professional to fix your zipper, fixing zippers is an inexpensive way to take jackets back into operation and a lot less expensive than buying a new piece of gear. Photo by Brandon Lampley.
Part 3: What to do when you can’t fix a zipper yourself
Sometimes your outdoor apparel or outdoor gear may be beyond self-repair because it may require sewing tools most people are unlikely to have at home. A bigger outdoor gear repair, such as on a tent door zipper, could damage the fabric of the entire piece of gear if done incorrectly. For these reasons, you may choose to have your outdoor gear repair done professionally. There are several companies that offer cleaning and durable repairs for their apparel and outdoor gear.
Mail-In Services
Patagonia offers repairs on any of its items. Most repairs are free, though some highly technical garments or tricky repairs may incur a small charge. Patagonia asks that you clean your gear before sending it in for repair. Some Patagonia stores may be able to do repairs in person.
Feathered Friends can repair the sleeping bag zipper on your Feathered Friends bag or quilts as well as broken zippers on Feathered Friends jackets. They also offer a cleaning service.
Arc’teryx offers repairs as well as cleaning on any of their technical apparel. Items that meet warranty requirements will be repaired for free; those that don’t can be repaired at a reasonable price. Arc’teryx will also clean your garments for an added, reasonable cost.
REI Repairs partnered with Washington-based Rainy Pass Repair Inc. to address issues on your tent, jacket, backpack, or sleeping bag. As a third party, these services are not free but are a great resource for cleaning and repairing gear that is not warrantied by the maker.
Rugged Thread is an outdoor gear repair shop based in Bend, Oregon but accepts mail-in orders. In addition to apparel, they can also repair zippers on your tent, backpack, or sleeping bag. Their zipper repair service is able to address issues like separating zippers, a damaged coil zipper, or broken teeth. Rugged Thread partners with brands to complete warranty and customer service repairs, so some repairs may be free.
Local Services
Working with a local gear repair business is a good way to extend the life of your outdoor equipment as you are able to show specialists exactly where and what issues need fixing.
Six Moon Designs maintains the most extensive list we’ve found of quality local outdoor gear repair shops around the US. It’s worth noting that not all sewers or tailors have the machinery and skills to repair outdoor gear, which often uses thicker and sometimes lighter-weight fabrics than everyday clothing. Six Moon Designs’ list includes outdoor gear repair shops in 17 different states, so you’re likely to find one in your region that can provide the services you need.
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Why You Should Trust Us & about the author
Stasia Stockwell is a lifelong skier who has spent an average of 50 days skiing each season since she could walk. She has taken classes on all-mountain skiing techniques and has her AIARE Level 1 avalanche safety certification. Her work in the industry spans from testing and reviewing skis for Backpacker Magazine to working on ski videos for Atomic skis.
Stasia has written for Backpacker Magazine, REI Co-op Journal, The Dyrt Magazine, and more. You can find more of her writing, gear reviews, and adventures on her website.
You can read all Stasia’s Treeline Review stories here.
