I am making a cozy for my Jetboil using light weight denim and thinsolite as well as one for my largest pot - have you made any, how and how did it work?

I have made a number of cozies using Reflectix(sp?) (the aluminum colored stuff with bubble wrap sandwiched in between)and aluminum tape. Made them for my pots, my coffee cups and even made them to fit dehydrated food pouches into.

I made a cozy out of closed cell foam and duct tape a few years back. Four seasons and it is still working just fine.

I made mine from Thinsulate and 1.1 sil nylon. Works great, and is supper light. I also have a foam pad, with a siliconized fiberglass fabric cover on one side (good to 600°) to set the pot on when it comes off the stove. The foam side to the ground does not slip around and the siliconized side keeps the pot from sliding around as well.

I spent a ridiculous amount of time this fall testing pot cozies with a thermometer. Mostly reflectix. Basically boiled 1 liter of water, turned off the stove, and waited. Did this a couple dozen times. (Yeah, no life; actually it fit in with an equally mundane activity I could do at the same time). My surprises: 1.) For the first 10 minutes or so, almost all the heat energy loss is from water turning to steam. A pot cozy does almost nothing during this first 10 minutes - unless, there's any wind. With wind, the pot cozy does a lot. The lesson I took away here is that your pot cozy really doesn't need to be all that bulky to be effective, it mostly just needs to block the wind. (A freezer bag cozy I think would not behave the same.) The most important thing is a tight fitting pot lid to keep the hot steam from escaping 2.) After 10 minutes, then the pot cozy makes a big difference. But, how long are you trying to keep your food near boiling? Again, I think this says you don't need a very bulky cozy, just mostly wind block in most cases. 3.) I lost surprisingly little heat to the ground after I took the pot off the stove. Like none. I think this was because the bottom of my pot was slightly warped, and so it didn't make much contact at all with the table I was using.

I think Dan's pot cozy is really good. It's not bulky - nice windblock with a bit of insulation. It looks like it's got a handle so you can lower it onto the top of the pot, and oversized a bit so it lowers on easily. And, it looks like it's got some kind of snap so it doubles as your cook kit bag. The only thing I don't think you need is the big pad for the bottom of the pot, unless you are camping on snow. You just need a little trivet of some kind.
So I'd copy Dan's, but maybe don't worry about the bottom? With denim, I'd go all out for style points with some kind of north woods stitchery theme.

quote NotLight: "
I spent a ridiculous amount of time this fall testing pot cozies with a thermometer. Mostly reflectix. Basically boiled 1 liter of water, turned off the stove, and waited. Did this a couple dozen times.
"

This is cool info. I've successfully used reflectix cozys/lids for rehydrating meals. Note that the reflectix is mostly thin plastic and I found out the hard way that it will melt if exposed to too warm a temp. A hot pot directly off the stove and into the cozy can sometimes be too warm! 30 sec or so after flameout and it is no problem.

All of the info is good but if you plan to use the cozy while cooking, as with most jetboil stoves, don't forget that with jetboil stoves there are often 'boil overs'. The denim will get wet and might be difficult to keep clean. Most often I boil as much water as I can get away with so if I'm not near the stove then it floods the cozy.

Good point PK. I put the jet boil cup in the cozy after cooking. This prevents the boil over onto the cozy. I bring the water to a boil, add the dehydrated meal, return to boil, take it off the heat source and put it into/or under the cozy - wait and eat when it is a reasonable yet warm temp.