: 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

Fantastic info - thank you, Paul. I was thinking a basic jumpsuit pattern would probably be a good starting point, too. A no-name waterproof/breathable fabric might get the cost down to 18-20 /yard and I'm estimating 5 yards might be required. Neck, wrist and ankle seals look like they can be had for a total of 80$, or so. (from the ossystems link you provided). The zipper definitley looks like the big ticket item. I have an email into ykk zippers right now to see if there is a less expensive source.

Boy, browsing through the pattern catalogs opens a whole world of creative possibilities. Would a handmade Gore-Tex teddy be such a bad gift on Valentines day?