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Question on Modding zippers on flight suit


Kyuzo Larkin

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Is necessary to remove all zippers, if the flak vest/cummerbund/boots end up covering up a majority of them on the suit? Also is it okay just to remove the zipper tabs and sew the zipper seams together? My suit has many zippers and it would be impossible to remove them safely. There is also a pocket for a knife. I will post pictures later of the flightsuit but I do believe 90% of the zippers will be in spots that will be covered by the hard armor, boots, and the cummerbund, and potentially the thigh patches and mud flap.

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I believe if the zippers are concealed you're alright... I believe the important thing is as long as it doesn't compromise how the overall costume looks w/ armor, flak vest, and bund then you should be alright.

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Are you modifying a Dickies work coverall? The chest pockets will be coverd by the flakvest & can be left there. How ever the utility pocket on the leg will have to be removed. The slash hip pockets can be left open as the belt will keep these closed. Havn't seen a Dickies in a while, & can't remember if they have the open slash pockets in the front hips. If so these will have to be sewn closed. These are work coverall & made to be worn over your normal day clothing so they might have an open slash to get to your regular pants while wearing.

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I'm a little skeptical about the zipper pocket around the leg, but maybe I just googled the wrong image? :/ That would need to be removed if it is because you'll be sewing suede with elastic around that area.

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The Rothco is all wrong. There are too many zippers & the pockets are "internal" meaning the zipper opens into a sack on the inside of the jumpsuit. If you can return it do so. If not use it for work around tge house. Buy a Redkap coverall & save yourself a lot of headache.

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