How to Repair and Extend the Life of Cargo Pants

Before you throw out those cargo pants with the torn pocket or worn knees, consider repair. Many common issues can be fixed at home with basic skills and materials, saving money while extending the useful life of pants you've already broken in to perfect comfort.

This guide covers practical repairs for the most common cargo pants problems. You don't need to be an expert seamstress—basic sewing ability and the right approach are sufficient for most fixes.

Essential Repair Supplies

Before you start, gather these basic supplies:

• Heavy-duty thread: Match to your pants colour; polyester thread is strongest
• Needles: Heavy-duty needles designed for denim and canvas
• Thimble: Essential for pushing needles through thick fabric
• Fabric scissors: Sharp scissors for clean cuts
• Iron-on patches: Various sizes in appropriate colours
• Fabric adhesive: For temporary fixes and reinforcement
• Seam ripper: For removing old stitching when needed

If you have access to a sewing machine with a heavy-duty needle capability, many repairs become faster and stronger. However, all repairs in this guide can be done by hand.

Fixing Torn Pockets

Pocket damage is one of the most common cargo pants issues. Heavy tools, sharp objects, and repeated stress cause tears at pocket openings and seams.

Repairing Pocket Seam Tears

When a pocket pulls away from the pants body at the seam:

1. Turn pants inside out to access the seam
2. Align the pocket edge with the pants body where it should attach
3. Pin in place to prevent shifting during sewing
4. Sew along the original seam line using a strong backstitch
5. Reinforce by sewing a second line parallel to the first
6. At corners and stress points, add extra stitches or bar tacks

Patching Pocket Holes

For actual holes in pocket fabric:

1. Clean up ragged edges with scissors
2. Cut an iron-on patch larger than the hole by at least 2cm on all sides
3. Position patch on the inside of the pocket
4. Iron according to patch instructions
5. For extra durability, sew around the patch edges

Reinforcing Worn Knees

Knees take significant wear, especially in work pants. Addressing wear early prevents holes from developing.

Preventive Reinforcement

If knees are thinning but not yet torn:

1. Turn pants inside out
2. Cut iron-on patches to cover the worn areas
3. Apply patches to the inside of the knee area
4. The interior patch adds a layer without changing appearance

Repairing Knee Holes

For existing holes:

1. Trim ragged edges around the hole
2. Apply an interior patch larger than the hole
3. On the outside, you can either:
   • Apply a matching patch for a utility look
   • Use darning techniques to weave thread across the gap
   • Accept the patched appearance on work pants
4. Sew edges securely to prevent patch peeling

Replacing Broken Zippers

Zip replacement is more challenging but still manageable for home repair.

When to Replace

Replace zips when:

• The slider no longer closes the teeth properly
• Teeth are broken or missing
• The zipper tape is torn or fraying

Replacement Process

1. Purchase a replacement zip slightly longer than needed
2. Use a seam ripper to carefully remove the old zipper
3. Note how the original was attached before fully removing
4. Pin the new zipper in position, aligning carefully
5. Sew close to the zipper teeth on both sides
6. Trim excess length at the bottom
7. Create a new stopper by sewing several times across the bottom

For fly zippers on cargo pants, this repair can be tricky due to the overlapping layers. If you're uncertain, a tailor can replace a fly zipper relatively inexpensively.

Fixing Frayed Hems

Hems fray from dragging on the ground and repeated washing. This is easily fixed.

Simple Hem Repair

1. Trim the frayed section with sharp scissors
2. Fold the hem up twice to enclose raw edges
3. Pin in place
4. Sew around the full leg circumference
5. Note: This shortens the pants slightly

Adding Hem Tape

For a neater finish or to maintain length:

1. Trim frayed sections
2. Apply iron-on hem tape to the raw edge
3. Fold and sew as desired

Addressing Seam Splits

Seams split at stress points, especially in the crotch area. Early repair prevents small problems becoming big ones.

Re-sewing Split Seams

1. Turn pants inside out to access the split
2. Align fabric edges where they should meet
3. Pin to hold alignment
4. Sew using a backstitch, starting beyond the split
5. Continue past the split on the other side
6. For stress areas, sew a second parallel line for reinforcement

Replacing Buttons

Lost or broken buttons are simple to fix:

1. Find a matching or similar button (save buttons from discarded clothing)
2. Position the new button where the old one was attached
3. Sew through button holes and fabric multiple times
4. Wrap thread around the threads between button and fabric to create a shank
5. Tie off securely on the inside

Restoring Velcro Closures

Velcro loses grip when clogged with lint and debris or when hooks wear out.

Cleaning Velcro

Before replacing, try cleaning:

• Use a stiff brush or old toothbrush to remove debris
• Pick out larger items with tweezers
• A fine comb can remove embedded lint

Replacing Worn Velcro

1. Remove old velcro by carefully cutting stitches
2. Peel away adhesive residue
3. Cut new velcro to size
4. Sew in place (don't rely on adhesive backing alone)

When to Repair vs Replace

Not every pair is worth saving. Consider replacing rather than repairing when:

• Fabric is thinning throughout, not just in one spot
• Multiple repairs are needed simultaneously
• The repair would cost more than half a replacement's price
• Elastic in the waistband has permanently stretched
• The pants no longer fit properly regardless of repairs

However, favourite pants that fit perfectly and have been broken in over time are often worth multiple repairs. The comfort of well-worn pants is hard to replicate in new purchases.

Preventive Maintenance

The best repair is avoiding damage in the first place:

• Empty pockets before washing to prevent stress
• Close zips and velcro before washing
• Wash inside out to reduce exterior abrasion
• Repair small issues before they become large ones
• Rotate between multiple pairs to extend individual lifespan
• Choose pants with reinforced areas for demanding work

Learning basic repairs adds years to your cargo pants while saving money and reducing textile waste. Start with simple fixes and build skills over time.