Building an A7l replica Apollo Moon Suit

I got busy last weekend and built a small loft in my shop. Storage is always a problem in a small shop, so I decided to go Up to solve the problem. This had some unexpected advantages. Since I set the bottom at the same height as my door, its now 7 foot or roughly 2 meters. This lowered the shop light I had in that area. The added light and proximity to the window seemed like the ideal place for my lathe.

After living with the new arrangement for a while, I think its the only spot in my shop for my lathe to live. The loft separates the area from the metal roof that gets quite hot in the summers with the sun beating down on it.

So here are some photos of my new lathe area, and small loft.

The part on the lathe is the last of 4 suit-side glove disconnects.

Apolloman asks ” how do you know the dimensions of the parts?”

I had access to some original parts that I made castings of. I use my castings as a guide.

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Here are some photos I took at the mill shop that is making the Helmet rings for me. They are as obsessed with details as I am. When compaired to the originals, they are exact reproductions. Getting very close to having the worlds best reproductions of the Apollo pressure helmet. I was lucky to find such skilled and talented people as Craig Brothers Machine Co. Inc. And practically in my back yard!  Now if you read my blog, you know I dont normally do endorsements. But Craig Brothers Machine Co. Inc are the best there is. So if you are around the central Ohio aera, and need this kind of work done. Call 740-756-9280

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The following pictures illustrate the steps I use to make a headrest/vent duct for an Apollo helmet. The process is vacuum forming, and I am using a heavy ABS plastic. The vacuum source is my shop-vac.

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Here are some photos of the seal arrangement between the pressure helmet and the ring on the suit. In photo 1 you can see one of the latches that are located around the ring. Just below it is the rubber seal. This is not an "O" ring in the normal sense, in profile it looks more like a windshield wiper.

In photo 2 you can see the latch in its full open or unlatched location. This allows the flange on the helmet to pass the latch and contact the seal. The lower part of the helmet flange is pushed into the seal forming and air tight connection.

In photo 3 you can see the flange on the helmet.

Photo 4 shows the helmet seated in the ring

Photo 5 is the same view as photo 1 except with the helmet fully engaged into the ring on the suit.

I hope this explains a bit more clearly the simple yet elegant methods used to seal up the A7L. Many of the same methods and hardware are still in use today.

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I have an acquaintance that runs an internet company involved in the sale of Space exploration related merchandise. Toys mostly and some “replica” space suits. These are mostly low fidelity generic looking Apollo and Shuttle suits.

And every so often he will call or email wanting to buy one of my suits, at an insultingly low price, usually less than I have invested in it.

Now I understand where he is coming from: He wants something that looks kinda’ like a space suit, that can be made quickly, doesn’t cost a lot. And he can sell a million of them.

I just don’t think he understands where I am coming from: I want to make something that looks, feels acts, and smells exactly like a specific suit from a specific mission. And I don’t care how long it takes to build it, or how much it cost. If I am building a Buzz Aldrin suit, I want it to be so close that Buzz would say “Yep, thats my suit.”

Now there is nothing wrong with selling a bunch of low fidelity toy spacesuits. But thats not what I am about. I want a suit that someone can look at or better yet, put on and say “Oh, thats what it must have been like.” or “Hey, now I know how that works!”

Well, I doubt if this person takes the time to read my blog, but if he does, perhaps he will understand a little more.

Alison, (And anyone else that is interested)  Here is how I see it: The male connector fits snugly inside the female on the suit, the red “O” ring provides the airtight seal between the outside of the hose end connector and the inside of the suit connector. The latches lock it all in place to prevent accidental removal. Now remember, the Apollo suits were only pressurized to 4.3 psi. So with the mechanical seal that little “O” ring would have been plenty.

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[caption id="attachment_426" align="alignleft" width="748" caption="Gas connector expanded view"][/caption]

I have spent a great deal of time studying the connectors and hardware on the Apollo A7L.  And having a question on the last post regarding the function of the connectors, I thought we could remove some of the mystery.

In the illustration above you can see most of the inner workings of a typical gas connector.  Not labeled, but clearly visible are two rows of latches, one above and the other below the "O" ring.

[caption id="attachment_428" align="alignleft" width="724" caption="Glove Disconnect"][/caption]

In this illustration we see the glove disconnects. The latches are labeled on this one. Both illustrations are from the "Apollo EMU Handbook, Apollo 14 to 17"

I'll let the illistrations speak for themselves. However, I would be happy to answer any questions.

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[caption id="attachment_415" align="aligncenter" width="225" caption="Sole of the pressure suit shoe or boot"][/caption]

I have been off my feet due to some minor surgery, so I have been working on some details of the boot soles on the ITMG. Above is my version of the sole.

[caption id="attachment_416" align="aligncenter" width="225" caption="Irwin training suit"][/caption]

Above is a photo I took at NASM of an actual A7L boot that was displayed for us in Amanda's office.

[caption id="attachment_418" align="alignleft" width="300" caption="Gas connector"][/caption] [caption id="attachment_419" align="aligncenter" width="300" caption="See the red "o" ring?"][/caption] [caption id="attachment_420" align="alignright" width="300" caption="Note the added screws next to the lock tab"][/caption]

Here are some photos of my latest Gas connectors. This one is rough and in need of polishing, But I think you can see what I am after here. The small screws and the "O" ring are new additions.

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Here is a nice photo of Amanda Young on the cover of Smithsonian Magazine. She takes care of the suits that went to the moon. And most of the prototype suits leading up to the famous A7L. Amanda is a true expert on space suit development, and just a sweetheart. She has been a great source of information for me.

Here are some of the connectors I have been working on.Stay tuned… more to come…

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Here are a few pictures of the right arm being sewn from some “new material” I have started to use.

Also today I spoke with the plastics company that is doing my helmet bubbles. They said they are starting to form the bubbles, but need to develop the proper technique. The first one “blew out”. But they are confident that with some adjustments, some good bubbles will be made this week.

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Its been a while since I updated the blog here. But not to worry, progress is still being made.

I have been working closely with the seamstress in an attempt to perfect the layout and patterns for the A7L. We are on the second full prototype. The first version was very good but had some placement issues. So she decided that was as far as we could go with that one. So she is busily sewing together the second prototype.

Meanwhile, the shoes or boots or feet of the pressure suit have always been a problem for me, they are a blond leather sole with Velcro and metal plates. These are attached to the boot of the suit and covered with Beta-cloth.

Well after some searching I found a cobbler close by that will make the soles for me, I just have to add the Velcro and plates. I think they will look fantastic.

I spoke with my plastics guy today, he said I will have bubbles this week. If that happens I can get the mill shop to start turning rings for them. Woo hoo! finally! The rings are larger than I can turn on my lathe, so I have to “farm them out.” I will be making extra helmets so I can offer them for sale. I don’t know the final price yet. I will keep you posted.

Also I have been burning up the lathe making connectors and other hardware. Not to mention working on the gloves.

Photos and up-dates to come, so stay tuned!

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