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  Work in progress: Shuttle ACES suit costume

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Author Topic:   Work in progress: Shuttle ACES suit costume
Teacher in space
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Posts: 60
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Registered: Sep 2013

posted 02-25-2014 09:05 AM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
I am currently making an ACES suit replica. Here might be people who someday will make their suit. That's why I will share images of making process and solutions.

Thanks for all of you, who have helped in different ways.

Patterns are 85% accurate. I left some small details and special shapes away.

Teacher in space
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Posts: 60
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Registered: Sep 2013

posted 02-25-2014 09:11 AM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
Sleeves are nearly ready:

Pockets and zipper done.

When these were ready I had already used 220 yards of orange sewing thread! Next 100 yards went when I sew pockets on their right locations.

space1
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Posts: 579
From: Danville, Ohio, USA
Registered: Dec 2002

posted 02-25-2014 10:25 AM     Click Here to See the Profile for space1   Click Here to Email space1     Edit/Delete Message   Reply w/Quote
That's a really impressive start!

apolloprojeckt
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Posts: 962
From: arnhem netherlands
Registered: Feb 2009

posted 02-25-2014 10:55 AM     Click Here to See the Profile for apolloprojeckt   Click Here to Email apolloprojeckt     Edit/Delete Message   Reply w/Quote
Looks really awesome!!!!

Charlie16
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Posts: 359
From: Italy
Registered: Dec 2010

posted 02-25-2014 12:45 PM     Click Here to See the Profile for Charlie16   Click Here to Email Charlie16     Edit/Delete Message   Reply w/Quote
Congratulations for the excellent work. I hope we can see more pictures!

garymilgrom
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Posts: 1771
From: Atlanta, GA, USA
Registered: Feb 2007

posted 02-25-2014 01:53 PM     Click Here to See the Profile for garymilgrom   Click Here to Email garymilgrom     Edit/Delete Message   Reply w/Quote
Beautiful work. Are you planning to sneak aboard the next shuttle flight?

Teacher in space
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Registered: Sep 2013

posted 02-25-2014 03:02 PM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
Thanks for great feedback! I hope I will get this to one piece still today.

Legs were tricky and I had to resew them three times. I just found out that zipper is 5cm too long. So I have to cut it and sew new ending part. Worst problem is that there is only 25 yards of sewing thread left...

p51
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Posts: 1060
From: Olympia, WA, USA
Registered: Sep 2011

posted 02-25-2014 03:27 PM     Click Here to See the Profile for p51   Click Here to Email p51     Edit/Delete Message   Reply w/Quote
Great job, I was following the build on the replica prop forum. Just curious, why STS-135 but a ESA crew?

Teacher in space
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posted 02-25-2014 03:40 PM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
I like the flight patch... and I can make me look like Sandra Magnus. And I am going to fool my students, even for a few seconds.

Finland has never had any astronauts. Tim Kopra is closest (his father was from Finland). So I can choose any mission.

I have several other mission patches so I can choose other missions too if I want.

Actually I would love to have mission patch with my own design and my name in it.

JBoe
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Posts: 454
From: Churchton, MD, USA
Registered: Oct 2012

posted 02-25-2014 04:33 PM     Click Here to See the Profile for JBoe   Click Here to Email JBoe     Edit/Delete Message   Reply w/Quote
Great job, that's awesome! Where did you get your orange cloth? I wrote to David Clark and received a sample of the orange suit material along with a patch that highlighted the programs it supported.

Teacher in space
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Posts: 60
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Registered: Sep 2013

posted 02-25-2014 04:43 PM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
This orange fabric is closest I could find. It is actually strong polyester meant for outdoor use (pillows or something similar). Weave is similar, but this fabric is just slightly transparent. I have to make lining or use orange garments under it.

I would like to hear opinion from all of you. What do you think: Should I leave suit looking new or would it look better worn?

JBoe
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Posts: 454
From: Churchton, MD, USA
Registered: Oct 2012

posted 02-25-2014 04:58 PM     Click Here to See the Profile for JBoe   Click Here to Email JBoe     Edit/Delete Message   Reply w/Quote
That's a tough one. Depending on how you want to display it, are you going for "off the factory floor" or this is what an astronaut wore or the closest to the "real deal." I would go for the worn look. How would you make it look worn without really staining it?

Teacher in space
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posted 02-26-2014 02:18 AM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
I worked until 2am... Just to notice in the morning that one seam is 1.5 cm off. All sewing thread is gone so I have to go shopping today.

Suit has now only pilot wings nametag with my name. Hopefully I will find a place that could do civilian winged patch latter.

apolloprojeckt
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Posts: 962
From: arnhem netherlands
Registered: Feb 2009

posted 02-26-2014 05:02 AM     Click Here to See the Profile for apolloprojeckt   Click Here to Email apolloprojeckt     Edit/Delete Message   Reply w/Quote
It look really great and you go fast with progress.

JBoe
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Posts: 454
From: Churchton, MD, USA
Registered: Oct 2012

posted 02-26-2014 06:57 AM     Click Here to See the Profile for JBoe   Click Here to Email JBoe     Edit/Delete Message   Reply w/Quote
That looks great! You sure completed it fast!

Ronpur
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Posts: 509
From: Brandon, Fl
Registered: May 2012

posted 02-26-2014 07:39 AM     Click Here to See the Profile for Ronpur   Click Here to Email Ronpur     Edit/Delete Message   Reply w/Quote
This is so amazing! I can't believe how fast you are going. It took me three days to do a pair of pants!

The Space Store does name tags.

Teacher in space
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posted 02-26-2014 08:03 AM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
I got more thread so I can continue today.

Still missing in this stage: rings around dcs and vent inlet (already had these, but I am not happy with them). Connecting piece for helmet neckring. Neckring has a "sadle" (dont know real name) that it rests on. I will likely make it from dense foam or something similar.

Hart Sastrowardoyo
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Posts: 2492
From: Toms River, NJ
Registered: Aug 2000

posted 02-26-2014 10:01 AM     Click Here to See the Profile for Hart Sastrowardoyo   Click Here to Email Hart Sastrowardoyo     Edit/Delete Message   Reply w/Quote
I believe Stewart Aviation carries the civilian wing namebadge.

Teacher in space
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posted 02-28-2014 08:34 AM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
As you have maybe guessed I am teacher. I teach biology, geography, physics and chemistry to teenagers. Teaching these to not so interested teens could be a problem, but since I love all these subjects, it has been even joyful. I am not full time teacher so I can easily give more effort to one lesson than teachers who have lots of hours. I do this because I also enjoy finding more about subjects I teach.

This spring I have planned space theme week. We are going to study our normal things, but from space or more specially International space station perspective. Focus will be mostly in geography and chemistry (combustion and so on). We will also study how space exploration is done and how humans can survive space. Main goal is to give teens an idea where school subjects are needed and give meaning for their studies. I am sure students will be surprised how many science expertises are needed in space station. I bet they think that astronauts know only astrophysics!

During the week will be school masquerade where I am going to wear this space suit I am making. For rest of the week and as lab coat substitute in future, I am going to wear this coat. I did not make this by my self; I just draw what I wanted. Velcro patches from space suit can be worn with this astronaut coverall inspired coat.

Teacher in space
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posted 03-13-2014 12:56 PM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
My project is in stand still since it is very difficult to find some one who would make neck ring for me. Everybody says it is easy to make one, and I should have it made of aluminiums. So far no one has promised to really make it. Soon I have to do it by my self. Our school has wood turning machine that I can and could use.

I have same problem with helmet visors. Not single one of companies or persons I have asked seem to have time or need for work. It seems I will have to make vacuum former and make the visors.

I still have one and half months, before this has to be ready.

apolloprojeckt
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Posts: 962
From: arnhem netherlands
Registered: Feb 2009

posted 03-13-2014 02:31 PM     Click Here to See the Profile for apolloprojeckt   Click Here to Email apolloprojeckt     Edit/Delete Message   Reply w/Quote
Do you not can use this type helmet?

Teacher in space
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posted 03-13-2014 03:00 PM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
I could use Russian/Chinese pilot helmets, but I would like to make real shuttle era looking one.

Helmet built is this far:

garymilgrom
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Posts: 1771
From: Atlanta, GA, USA
Registered: Feb 2007

posted 03-13-2014 03:22 PM     Click Here to See the Profile for garymilgrom   Click Here to Email garymilgrom     Edit/Delete Message   Reply w/Quote
Very nice! Keep up the good work Teacher!!

KSCartist
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Posts: 2616
From: Titusville, FL USA
Registered: Feb 2005

posted 03-13-2014 07:02 PM     Click Here to See the Profile for KSCartist   Click Here to Email KSCartist     Edit/Delete Message   Reply w/Quote
Teacher I believe I can be of help with a special designed patch. Feel free to drop me an email.

Teacher in space
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Registered: Sep 2013

posted 03-20-2014 03:23 PM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
Helmet looks like this now:

Right now it looks that I have to built my own vacuum former for making visors. Companies wont make single items or they are asking huge sum, even if they don't need to make molds.

Teacher in space
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posted 04-14-2014 12:34 PM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
This project has gone forward slowly.

I have all remaining supplies gathered and the mold for visor will be finished this week. We will make vacuum former during Easter and try to pull visor of PETG plastic. There is material only for two tries, so keep thumbs up.

Mold (over helmet) before surface coating.

Teacher in space
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posted 04-26-2014 02:25 PM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
Suit should be ready soon. Only straps are not in place and dyeing neck ring needs to be done.

Helmet has still lots of work left.

Teacher in space
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posted 04-29-2014 03:12 PM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
I have just few hours left and still so many things to do!

Teacher in space
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posted 04-30-2014 09:37 AM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
Today at school. Pose is horrible and cooling garments sleeves don't show. I thought that suit would be ready, but then there was many hardship. I accidentally broke one part I could not make at home. Neck ring surface did not work out the way I wanted, so I had to completely remake it twice. As result helmet was not ready this morning and. Now it is hinged just with simple bolts and pieces of plastic. I have to make proper hinges later.

Ronpur
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Posts: 509
From: Brandon, Fl
Registered: May 2012

posted 04-30-2014 10:06 AM     Click Here to See the Profile for Ronpur   Click Here to Email Ronpur     Edit/Delete Message   Reply w/Quote
That really does look amazing!

Norman.King
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Posts: 285
From: Herne Bay, Kent, UK
Registered: Feb 2010

posted 04-30-2014 12:08 PM     Click Here to See the Profile for Norman.King   Click Here to Email Norman.King     Edit/Delete Message   Reply w/Quote
I wish I had a teacher with your enthusiasm.

Well done, the suit is brilliant.

apolloprojeckt
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Posts: 962
From: arnhem netherlands
Registered: Feb 2009

posted 04-30-2014 12:48 PM     Click Here to See the Profile for apolloprojeckt   Click Here to Email apolloprojeckt     Edit/Delete Message   Reply w/Quote
This looks great, very nice done!!!!

Teacher in space
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posted 04-30-2014 01:06 PM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
Thanks for your comments!

If you wonder why this looks somehow odd: I am only bit more than 5 feet tall, so proportions will look very different than in real spacesuits worn by huge men.

space1
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Posts: 579
From: Danville, Ohio, USA
Registered: Dec 2002

posted 04-30-2014 02:14 PM     Click Here to See the Profile for space1   Click Here to Email space1     Edit/Delete Message   Reply w/Quote
Really impressive results. I hope your students appreciate your enthusiasm as much as we do!

JBoe
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Posts: 454
From: Churchton, MD, USA
Registered: Oct 2012

posted 04-30-2014 03:37 PM     Click Here to See the Profile for JBoe   Click Here to Email JBoe     Edit/Delete Message   Reply w/Quote
Congrats! I really like the suit and you can't even tell they "imperfections" that you wrote about in your post. I agree with the others, I too wished I had a teacher that enthusiastic. Great job!

onesmallstep
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Posts: 720
From: Staten Island, New York USA
Registered: Nov 2007

posted 04-30-2014 03:40 PM     Click Here to See the Profile for onesmallstep   Click Here to Email onesmallstep     Edit/Delete Message   Reply w/Quote
If you walk through the Kennedy Space Center Visitor Complex today wearing your impressive suit replica, I would bet many tourists would ask, "Can I have your autograph?"

Teacher in space
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Posts: 60
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Registered: Sep 2013

posted 07-16-2014 04:13 AM     Click Here to See the Profile for Teacher in space     Edit/Delete Message   Reply w/Quote
I found out that I forgot to post this link here.

If someone of you will make suit of their own, you can get tips and ideas from this article. Latter I will make similar post of helmet and hardware making.

Extra meter of fabric arrived last week, so one day I can sew gloves too.

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