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TK building a TB in PA


Kevin037

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I don't have patience or experience using forums.  Looking for advice/links on where to get my flight suit.  Gonna try and do my own sewing with the help of my wife so I'm looking for material list along with patterns for soft goods and boots  Pretty sure I will go with Studio Creations for my armor. I think I got it all.   Basically looking for material lists and links.  Thanks

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Most folks use a RedKap flight suit. But I've always found that the fabric is pretty stiff and rigid. Tend to get hot too. They're also short in the torso, which can make things uncomfortable.

This is an alternative that a few folks have used instead of the RedKap:

https://www.amazon.com/gp/product/B07BK87DYM/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

Undersuit mods are covered in Mickey's thread here: http://forum.501stpathfinders.com/index.php?/topic/19259-undersuit-mods/

Additional soft parts info are in these threads:

http://forum.501stpathfinders.com/index.php?/topic/19967-soft-parts-best-practices/

http://forum.501stpathfinders.com/index.php?/topic/19200-pouch-dimensions/

Let us know if you have additional questions!

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For the bund, cod, and pouches, Level 1 of the CRL only calls for "white fabric" for the bund and cod. However, Level 2 calls for smooth white cotton fabric.

Polished cotton or mercerized cotton is preferred, but at a minimum, smooth white cotton fabric.

Your pouches should be made of white canvas-type material (e.g., duck cloth).

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  • 2 months later...

There is no pattern due to varying sizes from one scout to another. However, checkout the link Chopper posted above on the Undersuit Mods. BikerScout007 has some measurements in that thread that will allow you to get started.

I would use chalk to outline the patches front and back on the flight suit and then post pictures for feedback. The armorers here are top notch and know their stuff. They’ll be able to recommend any adjustments needed. Then you can create your own pattern once the adjustments have been made.

If you’re interested, I have links to fabrics and materials in my build thread.  It’ll will give you an idea of what to look for when sourcing your own materials.  


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What was said is exactly right. I spent so much time trying to figure out those patches only to realize it’s not rocket science. Take a look at the CRL see where the patches end on the model and just make them end in the same spots on your leg. Chalk helps. I took old cloth and made some patches and pinned them on for pics.


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  • 9 months later...

First, you’ll need to seam rip the outer seam of each leg on the undersuit. This will give you access to pin and then stitch the patches to the undersuit using a sewing machine.

Below are images of my patterns for the front and back patches.

“A” on the front gets attached to “A” on the rear patch. This seam will line up with the inner seam of your legs.

“B” on the rear patch gets sewn to “B” on the other rear patch. This seam will come from the center of your crotch up your butt crack to the back of the undersuit.

“C” on the front patch gets sewn to “C” on the other front patch. This seam will run from the center of your crotch to the front of the undersuit.

“D” on the front patch gets sewn to “D” on the other front patch and this seam rides from “C” up the front of the undersuit to the zipper.

The remaining edges of the front and rear patches get sewn directly to the undersuit and form the outer edges of the patches.

It’s very easy to mixup your seams. I did and many others have too. Your best bet is to pin everything together first to make sure you have everything correct. Then pin it to the undersuit to make sure it’s laid out okay.

Once you’re good. Remove the pins from the undersuit and stitch seams A, then B, then C & D. Once all the patches have been attached to one another, repin it to the undersuit and stitch the outer edges to the undersuit and your done. Then you can restitch the seam of the outer leg and taper to fit if needed.

REAR PATCH
7d58885c76cc4991ea217ab343e990b0.jpg

FRONT PATCH
1710dfb2be43828d1bfaafb4b7bad9d1.jpg
Sorry for the crappy markups, I’m working off my phone using my fingers to draw.

It may look a little overwhelming but once you have it laid out it’s pretty easy. Make sure to use a heavy needle for your patches when sewing. I used 100/16. You want something rated for denim or leather anything lighter and it’s likely to break trying to push through the patch and the undersuit.


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