I am considering making either some insulated bibs or a pull-over parka with some good insulation like Climashield. I'm trying to figure out how to construct such garments without having "sew-through" needle holes that seriously compress the insulation and create cold spots. Anyone have any ideas how this is done, or know of any good videos?

Jaywalker: "I am considering making either some insulated bibs or a pull-over parka with some good insulation like Climashield. I'm trying to figure out how to construct such garments without having "sew-through" needle holes that seriously compress the insulation and create cold spots. Anyone have any ideas how this is done, or know of any good videos?"

No...but: I think the concept of mesh baffles is what is used in quilts to keep insulation from shifting and the compression issue you mentioned. Might be applicable.

Recommend further investigation via the reddit MYOG sub...lots of knowledgeable folks there.

You want to create over lapping layers with your insulation. Think how shingles work. Sew one end down then lay the other end over. Then sew just the inside insulation together so they don't shift around. When you sew the garment you will only have a few seams that go through. That’s how sleeping bags are made. If you can some how look at how sleeping bags are constructed you will understand what I’m talking about. North Face does this Technique.

Another thing you could do is sew one end of the baffle i was talking about in my last post to the outside fabric, and sew the other end that will be in another spot to the inside of the fabric. This way the insulation is held in place and won’t shift around and you will not have any through seams.