Rebuild

Turned a corner with a thought tonight: take it apart and rebuild. With the various pressure tests, I know the weaknesses, where the leaks are, and how to fix them. It's time to get the suit out of the seat, lay it out on the work table again, and make the final adjustments to all the sewing, fittings and plenty of other details. I think about eight hours of work will do it, and there's not a single thing to buy, I have every tool and material I need. First thing will be to do a good cleanup of the work area, sort out and clean all the tools, then clear my work area and prepare it for a final rebuild. One or maybe two weekends should get the suit properly sealed and ready for the pressure test with me in the suit, which I'm really looking forward to.

Actually, first is to formalize my task list, and then assemble exactly the items I need to complete each task. Then clean my tools, clear my head this coming weekend, and get a little more serious about locking in these final pre-test adjustments.

A quick list:

HELMET

* seal / remove helmet exhaust valve

* arrange intake hose warm-air defog unit

* spare UV/IR cover cutouts

* extend brow of liner cap

* reseal helmet / ring interface

* paint helmet with antiflame coat


ORAL-NASAL MASK

* add inner pressure shell

* add velcro connections to helmet liner cap

* ensure proper hose in / out lengths


HELMET HOLD-DOWN CABLES

* replace buckles with metal

* remove / secure sharp swage ends


GLOVES

* second hose clamp each

* hose clamp hold-downs

* antistretch gauntlets


CHEST FITTINGS (final tighten of all fittings)

* left = breathing gas out / extend hose

* center = electrical + comms / shorten through-fitting

and epoxy in lines

* right = breathing gas in / attach quick fitting and

attach hose hanger clip


ABDOMEN FITTING (final tighten of fitting)

* left = cooling hoses in + out / attach hose hanger clip


LEG FITTINGS

* left = suit pressurization gas in / replace fitting or

test for slow leak at SCUBA shop

* right = suit pressurization gas out / attach larger

control knob


HELMET HOLD-DOWN CROTCH STRAP

* reinforce


KNEE PATCHES

* add final grommets to each / add velcro position holders

to each


BOOTS

* final airtight coat


PRESSURE RESTRAINT GARMENT

* center chest through-hole

* reinforce all through-holes with third strength layer

* cinch underarm mesh

* replace helmet hold-down fittings with metal

* replace chest fittings wtih metal


FIREPROOF COVERALL

* build and attach with arrangements for parachute harness

* add arrangement for bail-out aviator's breathing gas

cylinder

* add arrangement for inflating life vest, sea dye and

small survival / map kit

LINER COVERALL

* sew vest tubes for threading in coolant hoses

* sew socks on to leg cuffs

* sew thumb loops onto arm cuffs