Building an A7l replica Apollo Moon Suit

I decided it was time to test fit the major parts of the ITMG to the inner suit. I had just

finished sewing the front to the two back halves.

I need to hem the bottom of the legs. Also the arm holes need to be larger. Then I’ll start working on the neck and the the rear entry flap/zipper.  The last cone on the sleeves that tapers down to the glove disconnects, and of course I need to cast and paint all the various hardware items and attach them.

Sounds like a lot, but I have the biggest part finished. And its down hill from here.

To this:

Popularity: unranked [?]

I have heard it said that “God is in the details”, well I doubt if God cares about replica space suits. But I certainly do! So I have been working on the small details I wished I had added the last time around.

Its hard to know how much is enough,

If it where feasible, I’d have every stitch, snap and fitting in exactly the right place. But this is after all, just a replica.

Here are the close-up pictures of the boots I mentioned last time, the seams are more visible here:

And I changed the shoulder area on the inner suit:

I think this will create a more realistic shape after the ITMG is attached.

With luck it will give that distinct A7L look I strive for.

Popularity: unranked [?]

I covered the tops of the boots in the Cordura nylon I am using for the ITMG and sewed them to the inner suit. The leg of the ITMG layer will come down to about the ankle, covering most of the top of the boot. Sorry for the lousy photos. When I get more time I’ll take some detailed pictures so yo can see the seams and the different parts.

In the second photo you can see part of the PLSS in the background. Also how do you like the new page layout?

Popularity: unranked [?]

I received the white boots I ordered, with the gum colored sole. I have been unable to locate anything with  the exact sole the original had.

A small milestone, I made a decision on which suit I am going to do. I like to pick a  certain crew-member and try to replicate (as close as I can) their suit. This time its going to be…Ed Mitchell’s Apollo 14 Suit.

Why? you may ask, well several reasons. Not the least of which is Ulli’s wonderful photo album over at the Apollo Lunar Surface Journal

This week I pinned the ITMG major parts together and test the fit on the inner suit.. That is when I realized I needed to move the UDC cover. I also was not happy with the shoulder area. I am working on a solution for that. I’ll post some photos when I get it fixed.

Oh, one last thing, I received the 36 inch white #10 zipper I ordered for the ITMG. Its the longest I could get in a number 10. It should be fine, the last suit had a 32 inch and it was ok.

Thats going to do it for today, I’ll post some pictures tonight.

Remember, if all else fails…try SCE to AUX

Popularity: unranked [?]

Sorry for the long time between post. Been working on getting the right arm of the ITMG just right. Its been several nights work. My approach has been to make a pattern, apply it to the cloth, and then test fit each piece. There are eight pieces just in the shoulder and upper forearm. And of course, each piece not only has to look right, but has to fit right to the last part.

Working from photos only, this leads to lots of discarded parts that are “just not right”.

The shoulder is a very complex arrangement of cones that are compound tapered. (what? compound what?) Yeh, its even harder than it sounds. Working out the geometry of each part in relation to the others while maintaining the stitching in the proper places is to say the least, taxing.

Ok, enough complaining. Suffice it to say, I am making progress.

I had planned to post some pictures of my shoulders and arms, (the suit, not mine…) but my son has my camera with the pictures on it. Perhaps tomorrow I will put them up.

On an other note: my friend Johan sent a very good mold of the pressure gage to me. I am working on a reliable method to rout out the face to allow a piece of Plexiglas to be inset with a gage face photo behind it. It seems promising, but I will have to make a template to guide my Dremel tool. My free hand attempts have been less than spectacular.

I promise to have a really informative post full of photos next time. (no, really!)

Remember if all else fails, try S.C.E. to AUX

Popularity: unranked [?]

I am expecting some better documentation on the pressure garment, so until that arrives I thought I’d work on some of the smaller items. The IV gloves or Intra-Vehicle gloves are todays project. I have been unable to locate a good source for the black rubber bladders, so we need to get a little creative.

So first head for the local home center or hardware and buy a pair of the large black chemical resistant gloves. You will also need: a small piece of thin black leather (Large enough to cover both palms and backs of both gloves) about 16 inches of 1/2 inch black nylon strap and buckle. Also something to represent the glove side disconnect. I use plastic castings.

The first thing you have to do is make a pattern for the leather that acts as the palm restraint. Here is what I did: I took an old pair of gloves, while examining the pictures of Armstrong’s IV gloves on the Apollo Lunar Surface Journal, I laid out the cut lines to make the restraint. I grabbed my scissors and cut the fingers and thumb off. Then I adjusted the holes to match as best I could the restraint area. (You only need one glove for this) Then I split the seam on the sides so I could lay it out flat. Trace this onto the leather and flip it over to do the other glove.

Stitch around the openings, and stitch up the sides. A strong sewing machine helps.

Next you want to cut two small vertical slits, just big enough for the nylon strap to slip through. One on the palm side, just above the thumb and one just inside below the “pinky” or smallest finger opening. Slip the strap through the slits, keeping it on the palm side. Then attach the buckle on the end nearest the little finger. Wrap the strap around the back of the hand and pass the free end through the buckle so it lays back over itself. attach Velcro to hold the loose end of the strap to itself.

Now on to the white nylon cloth. the circumference of the glove side disconnect is 14 inches. And the distance from the disconnect to the bottom of the leater is about 6 inches.

There are several seams and stitching deatails on these small parts, so in order to have plenty of clothe to go around: cut two pieces 24″ by 8″

Measure up 5/8th to 3/4 inch from the bottom and lightly mark with a pencil. This will end up being the bottom seam. Measure 15″ from one end and fold the cloth back on itself. Pin and sew a seam here. Fold about 1/2″ of the shorter piece back on itself about half way and make a seam. Tuck under the loose end of the short piece and sew it down making a third seam.

Insert the disconnect in the end of the black glove and wrap the cloth inside-out around the glove and connector. Pin the ends together tightly and sew up the seam. Turn the cloth right-side-out and slip it over the glove an pull it down over the end of the disconnect covering the black glove.

Slip the leather/nylon strap assembly over the glove and cloth. Pin the leather to the cloth and remove to stich on the machine.

You now have a pretty good representation of an Apollo IV Glove. Lather, rinse and repeat for the other glove.

Popularity: unranked [?]

After a couple of request for a detailed record of my trials and tribulations while building an Apollo A7l reproduction from the ground up. I was convinced to start this blog.

I hope to maintain a reasonable amount of construction info here. As well as cover my mistakes, and how I overcome them. (assuming I do…)

This first entry will be brief as I collect my thoughts and take some pictures of what I have so far.

My latest suit promises to be the most detailed yet, and I am trying some new construction methods. Starting with the base structure. I hope to build a three part suit mimicking the original, where as the ITMG will be covering a pressure garment shaped base structure. With a liner inside.

The biggest issues with the last suit seemed to be maintaining the proper shape while keeping the detail high. The monolithic construction was the cause many problems, that this time I hope to avoid.

Popularity: unranked [?]