1.0 Note: This process of replacing the panel is in reality a panel patch and is similar to that used in making a basic canopy patch. Because of the time and difficulty involved in removing and replacing the actual panel, that technique is best left to the canopy manufacturer. This technique is the more commonly accepted practice for major panel repair. The major issue to be dealt with in this technique is that of the amount of shrinkage that occurs during the repair. The larger the area of the panel, the more shrinkage there will be. The following procedure will describe a panel replacement on a block constructed, noncontinuous line canopy. A bias constructed canopy will be similar but more “fullness” will need to be allowed for in the cutting of the panel and sewing.

  1.1 Lay the canopy out inside out on the pin board. Pin the canopy in place placing tension on the seams and making sure they are straight.

  1.2 Cut a piece of fabric larger than the damaged panel by approximately 6" around all sides. Make sure that the weave of the panel matches that of the canopy. For a block constructed canopy, the bolt of fabric will run parallel down the radial seams of the canopy. For a bias constructed canopy, the bolt will run parallel to the diagonal seams.

  1.3 Trim one side of the panel to align the ripstop weave with the cross seam.

  1.4 Fold over the edge of the panel fabric approximately 3/4" and pin in place aligning the edge with the outside of the cross seam [Figure A].

  1.5 Smooth out the panel fabric over the damaged area and align the opposite edge over the opposite cross seam. Cut the panel fabric approximately 1" wider than the panel. Fold the edge under and pin in place. You will now have the top and bottom cross seams of the panel in place [Figure B].

  1.6 Stitch the outside row of stitching starting and finishing approximately 1" short of the radial seams.

  1.7 Take the panel fabric along the radial seam and trim approximately 3/4" from the outside edge of the radial seam. Fold under and pin in place. Repeat for the opposite radial seam [Figure C].

  1.8 Overstitch the end of the cross seam that was left open a minimum of 2" and proceed to and down the radial seam and then overstitch the open end of the cross seam. Repeat for the opposite side. It is advisable to hold a bit of tension on the seams as you sew to minimize the shrinkage.

  1.9 Turn the canopy right side out. Trim out the damaged panel along the seams [Figure D], leaving approximately 5/8". Also trim the excess edge of the panel as needed.

  1.10 Fold the edge of the canopy under the panel to create the seam and pin in place.

  1.11 Sew the inside of the panel seam in place. Again, hold tension on the fabric as you sew to minimize shrinkage.

  1.12 Remove the canopy from the machine being careful not to pull on the threads. Trim the threads. Inspect the panel.


  2.1 Check the weave alignment of the fabric panel to the canopy.

  2.2 Check for proper thread tension all around.

  2.3 Seams should be straight and parallel.

  2.4 The resulting size of the panel should match approximately that of adjacent panels allowing for shrinkage.

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