: Previous threads have convinced me to ditch the dreaded neoprene farmer john
: for a breathable Gore-Tex drysuit. Trouble is, I'd rather not part with
: 800 bucks right now. I realize that sewing my own would be an ambitious
: undertaking involving sewing the Gore-tex (which is about 30 bucks a
: yard), sealing and/or taping the seams and installing waterproof gaskets
: and zippers. Has anybody here tried it? Any sources for patterns and
: gaskets?

: Thanks,
: Jim
I'm not sure if this is suitable as a drysuit patern, or as a wetsuit pattern, but the one which looks most interesting came up as i was writing this. It is from Kwik Sew and is their pattern number 2335

Use this URL and then search the site for pattern #2335

http://www.kwiksew.com/Cold_Fusion/catalog/Frame.cfm

One manufacturer of commercial dry suits for SCUBA divers has an extensive description of the steps they go through to make their dry suits. Drysuits for paddlers are not quite the same as those for divers, so adapt as necessary.

http://www.kmedrysuits.com/exp-100.htm

One of the basic steps is making a paper pattern. There is a classic book on this called:

Patternless Fashions: How to Design and Make Your Own Fashions!: by Diehl Lewis and May Loh

Use the following URL to find the lsiting for this book on Amazon.com:

http://www.amazon.com/exec/obidos/tg/detail/-/0874914132/qid=1061352911/sr=8-1/ref=sr_8_1/002-5442412-6151264?v=glance&s=books&n=507846

Strangely titled, the book shows how to mark your "pattern" diretly on the fabric, OR to make a pattern on paper. I think "patternless" refers to not using commerially printed patterns. The book deals mostly with women's clothes, and measuring women -- however there is a chapter about measuring men and children, and making garments for them. You would really only need to read the general comments at the front of the book and those few pages on menswear, so if you can find a copy of the book at your library you could just photocopy the pertinent info in a matter of minutes. Or, if your library does not have the book in their collection, ask a librarian to try to get a copy through "interlibrary loan". Print out the ISBN number from the amazon.com web page and it may be easier for the librarian to find this.

The basic garment you would be mimicking would be a jumpsuit (or snowmobile suit) and this has some interesting construction similarities with building a kayak. First you make the bottom and top, and then you join them in the middle. If you are working with rubberized materials you would be making this by "Stitch and Glue" techniques

Other patterns you might consider would be those for jumpsuits which you can pick up at your local sewing store.

Take a look at some of the patterns offered by Greenpepper. You might be able to modify their black butte jumpsuit, or their williamette racing suit. they also have information on sewing with breatheable fabrics.

http://www.owfinc.com/Hardware/Patternslist/GPpics.htm

By the way, Gore-tex is not your only choice in breatheable fabrics. since you are making your own gear, you can make the pants from one material and the top from another. Or, just put in large panels from your breatheable material and make the cuffs, pockets, shoulder yoke, collar, facings, etc. from a less expensive (non breathebable) material. The actual area that "breathes" will be reduced only slightly, but you might be able to save some money.

If you want to find a "generic" pattern to start with, consider one for a 2-piece jogging suit, and then joint the tops and bottom. Simplicity has this in their catalog, and it is a very basic, very simple pattern to start with.

http://www.simplicity.com/s2b.htm They list it under the tab for "sleepwear, unisex, and men"

Similarly, McCall's pattern 3860 might work for you:

http://store.sewingtoday.com/cgi-bin/mccallspatterns/shop.cgi?s.item.400003860=x&TI=40013&pageNum=1&M=&UK=30817427

You might want to make a mock-up of your dry suit out of inexpensive muslin, by working from this. Sew this together with a long, loose stitch which is called a "basting" stitch. Modify it by sewing the top to the bottom, and adding seals and zippers where you wish. Then, if it fits right you can simply pull out the basting stithes, press and spray-starch the fabric, and then use that as a pattern for cutting your expensive fabric.

The fabric supplier may be able to give you more leads on finding patterns for your dry suit.

As for a supplier of parts and seals, try:

O.S. Systems, Inc.
Mail: PO Box 1088, Scappoose OR 97056-1088
Shipping: 33550 SE Santosh St., Scappoose OR 97056-3608
Phone 503-543-3126 Fax 503-543-3129 - e-mail info@ossystems.com

their URL is:

http://www.ossystems.com/repair/seals.html

I've never dealt with them, but their web site seems to have the parts you would need.

A thought ocurred to me as I read their page and saw that certain parts were meant for drysuits with a particular cirumference in the pants leg or arm sleeve: It might be good to buy the seals first and then decide on the measurements of the garment which would best fit the seals.

Here is one source for dry suit zippers:

http://www.neoprenecrafters.com/repair.htm

Just eyeballing the prices for the parts and the ost of a new drysuit, I'm not sure you are going to save very much by making this yourself. Of course if you have a body which is hard to fit with off-the-rack styles, you may be forced into going with something which is custom tailored -- and here you would save big bucks by doing your own sewing.

Hope this helps. Good luck withyour project.

PGJ