Dart

I've been using it for the past bunch of troops. It definitely adds some fun when you're just standing around. One thing that I found out was that it also helps to drain the battery on my Aker amp faster since even when there's no noise, the amp is still being activated. No big deal, I keep my amp charging cable with me.

Go to Home Depot/Lowes and get some weather trimming foam. They come in all sorts of widths and it's just a matter of cutting and sticking them into place. I use that in my bucket and it works just fine.

Definitely go heavy on the glue. After you've stretched the toe cap, make sure you get a really good layer of goop/e6000 before you slap the toe cap back on. I find that if you use a plastic knife it makes it easier to spread the adhesive around. Don't be surprised if you use most of a tube when you're finally done the boots.

Congrats!

^Agreed.^ If it's a military flight suit and it's made of nomex or another synthetic, it'll be much more difficult to get the dye to set.

The only thing I have to say about that one is if it's made of cotton, you'll be soaked if you're on a decently long troop. Cotton just absorbs moisture. Being that you're downunder, I might reconsider based on the comfort of wearing a wet rag on your head, hahaha!

^Agreed.^ This is something that I can see being available *maybe* next year or late this year. Can't rush the guy.

They look just fine. Just make sure to give the cuts nice square corners and they'll look great.

There's two ways you can do the buckle - either run the strap through or cut pieces to make them functional. From what I understand, on screen they were just run through the buckles. If you take a look at the MoM pics, there should be some good shots of how things should be done. As for the length of the strap, you want to make sure that the boxes don't hang too low. Ideally, there should be no more than 2-3 inches from the bottom of the belt to the top of the box. Also, if you look at the photos of the straight on shots, you'll notice that the bottoms of the boxes don't go below the point where the codpiece tucks under. Also, the boxes should be on the sides of your leg so when you're fastening the loose ends to the back, make sure they come fairly close to the buckle (or whatever you're using to fasten your belt). The lengths are different for everyone, so play around with them until you get it looking right on you.

Consider this a third. You might be able to get the cheaper stuff now but you'll end up having spent more than if you just saved up for something decent.

That's kinda neat! Thanks for sharing.

Yeah, I'm adding this to my suit as well. I've got an older iPod Nano that I never use so why not use it now? Hooks up nicely to my Aker amp and I can just put it all in one pouch. Giving it all a test run at this weekend's Wizard Con up here in Toronto.

I usually run a 12v squirrel fan with a 9v and a switch. I believe there was someone here that was still selling fan kits. I've actually got mine installed in the snout. Drilled out the aerator and the faceplate. Works a treat!

One thing you can consider is to put some ventilation panels in your undersuit and in the hidden parts of your flak vest. That's what I did. Just got some moisture-wicking mesh cloth from the fabric store, got my mom to sew two long panels in the front of my undersuit and one larger rectangular panel in the front of my flak vest (which is also sewn to my 'bund). I've trooped in some decent heat and humidity and while I've still sweated, it was managable. Also, make sure that you wear a good moisture-wicking balaclava and socks. Makes a huge difference.

Just don't stretch it too tightly across the laces or you'll make it difficult to slide your foot into your boot.

Good luck with the vinyl. How thin is that stuff? Asking because you'll need to stretch it over the toe of your boot completely (ie. no cuts at the laces). If you haven't already, I'd heat the vinyl up and give it a bit more of a stretching at the laces. As for whether it'll be approved or not, it's really up to your GML.

Give yourself some room. It's not so much that the chest piece rides high; the bottom should be about where the bottom of the back armour sits. Ideally, the top of the tank should be flat, not angled towards you. If you haven't already, match the top straps up and put some tape over them. Try the armour on and see what it looks like in the mirror. Then decide how to make your cuts. One thing I can suggest (that I also did) is after you cut the front straps, check to see how the curve sits against the front of your shoulder. I had a sizable gap so I just took my heatgun and a small piece of wood and flattened the curve out a bit. Sits much nicer now.

Good on ya for getting Lancified! Also, my condolences for your loss.

Thicker is better when making the barrel of the boot. That way, it'll help hold up the holster/blaster just by virtue of its thickness. As for working it over the front of the boot, heat is your friend.

Lol! It's ok, you're not the first to wear that suit backwards. As far as I know, MC doesn't make Fibreglass armour anymore. He is still making armour so you might be able to get away with just ordering a chest plate. That'd probably be the easiest thing to do. Then you'll just need to weather it to match the rest of your gear.

Is the rest of the armour fibreglass? From that angle, it does look a bit on the small side. Also, you might want to consider pulling those leg boxes up. Ideally, they should only be about 2-3 inches from the bottom of your belt.

The stuff you want is marine vinyl. You don't want the stretch vinyl since it's wayyyy too thin.

The covers are 7/8" in diameter and about 3/32" in depth (22mm x 2.5mm)

When you're doing the top straps for the chest/back, just wear a t-shirt or your flightsuit. Most of the adjustment will be from the bottom soft strap anyway. One thing you can do to check how it fits is to put the chest and back on, tape the top straps where they are and check things out in a mirror from the side. Ideally, you want the bottom of the chest and back to be about the same height or so. Take a look at the screen grabs and you'll see what I mean. Now, I don't know if you're a big dude with a deer gut or just a spare tire, but make sure you don't bring the chest armour up too high. Don't wanna look like it's chokin' ya. BTW, nice TD. Looks good.

When I did mine, I attached the ends so that the boxes were hanging no lower than the bottom of my cod (buttoned in place). I also made sure they were on the side of my leg, not closer to the front or the rear. I think I just measured the distance of the strapping between the front of the box and the buckle and then made it the same length on the back side.