: Fantastic info - thank you, Paul. I was thinking a basic jumpsuit pattern
: would probably be a good starting point, too.

Home Depot sells disposable Tyvek (or polypropylene) jumpsuits for about $10 to $12, and I'm sure other stores have the same thing. You can practice modifying these, by sewing on the extra fabric for that entrance tunnel, and if you find an entry method that works, just cut the tyvek jumpsuit along the seams to make patterns.

These people sell these jumpsuits by the case. For a case of 25 polypropylene overall it is just $40. you can amke a lot of cutting mistakes with stuff that cheap -- and you can wear these while sanding, too!

http://www.bestbailers.com/comgarcovwzi.html

Or, look at their microporous suits.

http://www.bestbailers.com/micmaxhoodbo.html

They are pretty light weight, but it appears they are waterproof, but breathable. And, disposable! At $86 for 25 of them it would be a steal if they worked out. Make your own "seals" for the arms and legs from (recycled) rubberbands applied over the outside of these. As for a neck seal -- well -- I wouldn't use rubber bands here, but you might be able to buy a latex seal and wear it over the garment instead of under it. It might not be perfect, but if it keeps your flannel liner dry then it would be "good enough"

PGJ