Scout Trooper – Flight Suit – Modding, Completed

Butt/Mud Flap…

Now let’s attach the Butt/Mud Flap…

I centered the Velcro on the back of the Flight Suit, just below the waist band.

Sewing the Velcro…

Velcro install completed.

Butt/Mud Flap in place…

Front view of the Thigh Patches/Straps while wearing the Flight Suit.

Rear view of the Thigh Patches/Straps and Butt/Mud Flap while wearing the Flight Suit.

I won’t lie, this part of the build has been the most taxing, so far. I’m usually fairly adept at sewing things, even though I’ve never had any professional training but working with the suede and trying to get things all to fit correctly really pressed my patience.

I’m glad I stuck with it, though, because I think it turned out pretty good in the end.

My advice: No matter what, keep going. If you make a mistake, tear it apart and redo it. And never settle for “good enough”, always strive for excellence.

Scout Trooper – Flight Suit – Modding, Continued

Butt/Mud Flap…

With the Thigh Patches done, it’s now time to add the Butt/Mud Flap…

This will be cut from my remaining suede material.

I cut a straight line across the top part.

Then cut a straight line down the left side.

By my measurements, I need the length of the flap to be 9 inches. So, I cut it at that length…

For the width, I figured it should be 10 inches.

And, here it is…

Rather than sew it directly to the Flight Suit, I will use Velcro so it can be removed…

Sewing the Velcro to the top of the flap.

Flap with the Velcro attached to the top…

Scout Trooper – Flight Suit – Modding, Continued

More Fitting…

Last night, I tried the Flight Suit on, and the fit was horrible. I was very discouraged, and decided just to walk away from it, and try to tackle it another day. So, this morning I will try working on it with a fresh mind…

The first part I decided to work on was the torso. The crotch area seemed to hang way too low, so I found that by bringing in some of the torso I could raise the crotch area. I used the horizontal waist band as a guide and ended up tucking in about 2 inches of material.

I then stitched it up, using the same stitch lines that were already there. I tried the Flight Suit on, and the fit felt way better.

The thigh area of the Flight suit is still a bit baggy, so I’m now going to start working on firming it up. I’m thinking I will start by bringing in the inseam a bit more.

Looking at my original stitch job, I didn’t really get it correct anyway. The front and back aren’t aligned correctly, plus I don’t think I stitched the inseam in deep enough because there’s a large hole that shouldn’t be there…

Ripping out the old seam…

Seam opened.

After making sure everything is correctly lining up, I stitched the inseam back together using the new guideline I sketched in…

Inseam resewn…

All of the pieces are now aligning correctly, and the big hole is gone. I knida dreaded having to redo this part, but now that it’s done, I’m glad I actually took the time to do it. The fit of the crotch area is way better. Now, I just need to tighten up the upper thigh area.

I tried the Flight Suit back on and made some rough marks to indicate how much material needed to be removed…

I used those marks to figure out the actual stitch lines for both legs….

I then ripped the old seams open.

This allowed me to redo the thigh straps. They were now way too loose. I ripped the seams on the back part to remove them, remeasured the length they needed to be, cut them, and then restitched them back into place.

Once the strap work was completed, I sewed up the thigh seam. Time for a new test fitting. I kinda need to be a bit of a contortionist to get into it, but this Flight suit now fits like a glove.

Scout Trooper – Flight Suit – Modding, Continued

Thigh Patches…

Continuing the installation…

Front crotch seam is now sewn together…

I probably should have re-sewn the inseams before I actually added the suede patches. Now, it’s impossible to get the machine to this location, so, I’ll have to stitch it by hand…

One side done…

And, the other side done. Not the prettiest stitch job, but…

Now, I just need to sew up the new inseam.

And, done. Time to try this thing on to see how it all fits with the suede patches in place…

Scout Trooper – Flight Suit – Modding, Continued

Thigh Patches…

Now, time to attach them…

I’ve read that keeping the suede in the correct position while sewing is difficult. So, I’m going to try using this to “tack” them in place…

I cut a piece that will cover the area, minus the seam allowance.

Then, ironed it on.

One piece done…

Both rear pieces done…

Front pieces done, as well…

Ironing the first piece to the Flight Suit…

Tacking complete…

To be able to get the sewing machine inside to attach the suede, I had to rip out the entire front crotch seam…

Sewing the suede on…

Sewing the second front piece on…

Both front pieces attached to the Flight Suit.

Following the same process, I got the two rear pieces sewn to the Flight Suit.

So far, so good… I started sewing the four pieces together, with the “butt” seam first.

For the main crotch seam, I was looking at the old seam on the Flight Suit, and made a huge mistake. I was thinking I made the seam allowance too wide, and cut the suede back to the fold on the Flight suit seam. I’ll now need to rip the rear pieces off, and re-cut them…

Removing the suede…

Ruined patches removed.

New rear panels cut out…

Heat n Bond applied…

New rear panels sewn to the Flight Suit…

I used blue painter’s tape to mark the area where the thigh straps will go.

I then ripped the seam, inserted the elastic in 1 inch, and ran a new stitch to secure it in place.

I followed the same process to install the thigh strap on the other side of the rear patches.

I then lined up the front and back and used blue painter’s tape to mark where the straps will go on the front.

Marked and ready to rip the seam and install the thigh strap.

Thigh straps all installed.

“Butt” seam, resewn.

Scout Trooper – Flight Suit – Modding, Continued

Thigh Patches…

I have been procrastinating working on the Thigh Patches because they seem like a very daunting project. I guess it’s now time to just jump into it…

First thing I did was try to get a rough idea of where my Knee Armor would sit. So, in a sitting position, I marked the top with a piece of painter’s tape.

This was then transfered to the other leg, as well.

The suggested sizing of the Thigh Patches is that they need to end roughly 2 to 3 inches from your knee cap. For me, it would make the inseam of the suede pieces about 10 inches. So, I marked that with a safety pin.

While wearing the Flight Suit, I then marked the front area approximately where the crotch began to go under. Another suggested measurement is the width of the Thigh Patch at the begining of the crotch area should be about 3 1/2 inches. So, I marked that, too. This now gives me a rough interpretation of where the Thigh Patch needs to go…

Using some newsprint paper, I did a rough sketch…

The template, cut out, with 1/2 seams added. I then used the template to cut a piece of felt and attached it to the Flight Suit with safety pins. I put the suit on, and the shape just wasn’t right. So, I made some mental notes of what needed to change on the template…

Making a new sketch…

The new template, cut to size…

I cut out a new piece of felt, and safety pinned it to the Flight Suit. After trying it on, it looked much better, this time. On to the rear…

I started by making a copy of the front template and used that to create the back template.

I cut out a test piece, in felt, and then tried the Flight Suit on. It seemed to look pretty good.

So, I now have my templates…

The dreaded part… Cutting up my suede…

One piece done.

Both rear panels cut out.

One front panel done.

Both front panels cut out.

All in all, this wasn’t really as bad as I thought it would be. It did take about 3 1/2 hours of continuously putting on the Flight Suit, testing pieces, making adjustments, etc. But, I think it all paid off. I guess we’ll see, once I begin sewing the suede pieces to the actual Flight Suit.

Scout Trooper – Flight Suit – Modding, Continued

Detail Work…

Making it more screen accurate…

I’ll be hemming this using “mitered” corners. First step, pin the 1/2 inch hem on all for sides, leaving the corners.

I then trimmed the excess material on the corners, and tucked it into the inside, temporarily pinning the corners into place. This gives me a 1/2 inch seam all of the way around. This was then pressed with an iron.

After pressing, the raw seam edges got folded in, making the final seam 1/4 of an inch. This was then pressed with an iron.

Time to sew…

The finished seam, on the side that will show…

Time to add the Velcro for the closure…

I added two strips of 3/4 inch Velcro to the inside of the flap…

I then pinned the flap into position on the existing collar.

And it was sewn into place…

The other Velcro was positioned onto the collar…

And, then sewn into place.

Finished collar.

Scout Trooper – Flight Suit – Modding, Continued

Detail Work…

Making it more screen accurate…

Time to make the Flight Suit more “fitted”. The first thing I did was turn it inside out, and put it on. I used a piece of chalk to make some marks where I felt it needed to be brought in. Then. I placed safety pins along those marks and tried it on, again. I made a few adjustments with the safety pins, until it felt comfortable, and I was able to move around with it feeling like it “bound” me up too much.

Once I was happy with the safety pin placement, I used the chalk to make a line from the arm cuff, all the way down to the waist area.

The result…

I then put straight pins along the chalk line to keep the material together…

The coverall has a solid piece of material that runs around the waist area, that covers the seam where the upper and lower portions are joined. In order to keep this from bunching up, I’m going to try cutting it. Hope this isn’t a mistake…

Here goes nothing…

Waist band cut, and seam revealed.

I then transferred the chalk line to the other arm and side, pinned it, and cut the waist band…

Time to go under the needle…

First side sewn. I gave the waist band area some extra stitching to hopfully reinforce where the band was cut.

Other side sewn, and the waist band reinforced.

For the bottom part, I took a pair of my blue jeans that fit pretty well, and used those to kind of “eye ball” the sizing a little better.

After adjusting the safety pins, I used the chalk to make a line.

The result. For the very bottom, I actually brought it in a little more than my blue jeans, so that there will be less fabric to deal with inside the boots.

Legs marked, and pinned.

Time to sew…

One leg done…

Starting at the top of the other leg, I ran another stitch through the waist band area.

Other leg completed.

Now, adding the “zig zag” stitch to help keep the seam allowance from fraying…

“Zig zag” completed down one entire side…

Starting the “zig zag” for the other side.

“Zig zag” completed down the other side.

Time to trim off the excess fabric…

All excess material removed.

The amount that was removed.

Not really sure how I missed this, but there’s another pocket on one of the legs that I probably should have removed before I started working on the fitting…

Some quick work with the seam ripper, and the pocket has been removed.

Seam repinned.

Seam resewn.

Time to make the “mandarin collar.” This is one of the back pockets that was removed.

The collar piece needs to be 3 inches by 5 inches. So, I cut my rectangle to be 4 inches by 6 inches. This will give me 1/2 inch on each side to use for hemming.

Scout Trooper – Flight Suit – Modding

Detail Work…

Making it more screen accurate…

Time to get to work on the Flight Suit. These back pockets need to be removed…

Using a seam ripper, pocket removal is fairly simple.

One pocket removed…

Two pockets removed…

Back of Flight Suit with the pockets removed.

These front pockets don’t really need to be removed, but I’m going to remove them anyway.

One more pocket removed…

And, last pocket removed…

Front with the pockets removed.