Abstract: An improved quilting apparatus and method for automatically providing a variable sewing area (VSA) independent of the throat depth of the sewing machine used and X/Y carriages on which the sewing machine is mounted, comprising a rotatably-powered take-up roller mounted on laterally movable carriages, a tension system for continuous tension on fabric and batting, arm-mounted or sewing machine-mounted sensors that detect proximity or engage fabric on the take-up roller and cause rotation of the take-up roller so that it is out of the way of the advancing or returning sewing machine. The inventive VSA system includes a microprocessor-based controller for automatic operation, which controller interfaces with PC operated quilting programs that drive powered X/Y carriage systems to allow sewing of quilting patterns much larger than the throat depth of conventional sewing machines.