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BSA Merit Badge Sash Closeup

How to Shorten a BSA Merit Badge Sash

February 23, 2022 Sarah Coggins
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Our son crossed over from Cub Scouts to Boy Scouts just before the start of the pandemic. During the many months at home, he earned 11 merit badges taking virtual classes. Shortly after his first Court of Honor in the fall of 2020, we purchased a Merit Badge Sash for him to display them.

BSA Merit Badge Sash Title

The sashes come in multiple lengths. Knowing he will get taller (possibly as tall or taller than his father?), we opted for the largest sash so it can grow with him. Only catch? We need it shorter now. Here’s how I shortened it and will be able to adjust to “grow” with him in the next few years.


  • BSA Merit Badge Sash (ours is 40″)
  • Quilter’s Square
  • Fabric Pencil
  • Straight Pins
  • Needle
  • Thread – I used Coats & Clark color 6360 Bronze Green.
  • Scissors
Cat Inspecting Merit Badge Sash Supplies
(Nosey cat optional.)


Step 1 Fold the merit badge sash inside out and gently hand press the point seam flat.

Fold Merit Badge Sash Inside Out

Step 2 Use your quilter’s square to measure and mark a new seam. I set ours at about 3-3/8″ focusing on keeping the 45° angle aligned with the edge of the sash. Mark the line with a white fabric pencil.

Measure New Seam for Merit Badge Sash

Step 3 Use straight pins to secure the sash fabric at the hem line.

Straight Pins Holding Sash Layers Together at Hem Line

Step 4 Sew along the hem line using larger stitches (the goal is to make this easier to remove when your child grows). If you do not have a sewing machine, you can sew this by hand.

Sew New Hem for BSA Merit Badge Sash

Step 5 Return to your flat surface. Place sash laying flat as it was when marking the hem. Now fold the top piece of fabric forward along the hemline.

Fold Sash Fabric at New Hemline

Step 6 Carefully flip over folded sash. Tack at corner with a few stitches to secure the fold.

Tack the Corner of Sash to Secure Fold

Step 7 Fold the pointed end to the main fabric and tack in place. Then hand stitch along the open edge. Remember these stitches will be removed when your child grows and you want to lengthen the sash later.

Tack Bottom Corner to Complete Hem

Step 8 Turn the sash right side out.

Completed New Merit Badge Sash Point After Hemming

It’s now ready to sew on merit badges and wear!

Shortened BSA Merit Badge Sash

Don’t forget to check out our Scout Uniform Organizer tutorial – perfect for keeping track of all the extras including Scout Handbook, neckerchief, slide, and belt.

About Me


Hi! I'm a DIY and craft obsessed mom to 2. I have my hands covered in sawdust or paint any given day. My husband and kids join me in many of our projects. When we aren't creating at home, we're creating memories in our many adventures. Join along! Read More


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