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DIY Kestrel Clone

I am doing plastic buckles on the legs. I only went heavy duty on the waist where it could keep me from falling out if I manage to get upside down or something breaks. In fact, I put those leg straps on intending to cut them back off if I don't think they do much in testing.

I have yet to hang in this, but I'm heavier than average and want to give it some good bouncing, full weight pulling and stress it every way I can think of. If satisfied, I'm making at least one more for my son.

Costs into them:

1000d cordura, 1yd x 2yd, $21.90 (eBay)
1 3/4in Mil spec dive webbing, green, 10yd, $15.99 (eBay)
1in heavy nylon tubular webbing, black, 10yd, 12.95 (Amazon)
1in Mil spec binding ribbon (grosgrain), green, 5yd, $4.92 (eBay)
Coats & Clark heavy duty bonded nylon upholstery thread, brown, 150yd x 3, $14.34 (Amazon)
ISC buckles x2*, $44 (lowayusa.com)

For the leg adjusters I shamelessly cut off shoulder strap parts from an old backpack that had holes. Recycle. I may go to Hobby Lobby or Joann to find buckles for the leg straps, or maybe get them from an old sleeping bag.

So around 114 total, or $57 each in materials, and it took me 12-16 hours to do one, starting at "Hey, look, a sewing machine! How do you use a sewing machine?" The second will go much faster and the stitching will be way better with less redos, and parts I had to go over 4x because I was crooked, missed, etc.

* Lowyusa has a $50 min order and probably would scale at volume. I ordered 4 at 17ea plus shipping in case I like them for other things too, which came to $88. Shipping sucks, but they're heavy. I might resell leftovers later.


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What are the specs on the Coats and Clark thread you are using? I know you guys are trying to use what’s readily available. Here’s a good article I would recommend.

https://sailrite.wordpress.com/tag/nylon-vs-polyester-thread/


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What are the specs on the Coats and Clark thread you are using? I know you guys are trying to use what’s readily available. Here’s a good article I would recommend.

https://sailrite.wordpress.com/tag/nylon-vs-polyester-thread/


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Thanks for the read. I may order some Tera 40 to compare before doing another. I looked for it briefly on your word when I'd run out before, after I already ordered more of what I started with, but could only find it at JoAnn where the naming changes confused me. I saw a gutermann rep clarify the naming later, but then my local store didn't have it in.

I can't find the original recommendation now, but I found the link to the C&C thread I used on a hammock or climbing site.

This is it the thread: COATS & CLARK Extra Strong Upholstery Thread, 150-Yard, Chona Brown https://www.amazon.com/dp/B001EL5U0E/ref=cm_sw_r_cp_apa_.urRAb9Q1DYQT

I don't know how they're tested for strength or stretch officially. I know I had to give a very solid tug to break 1 thread of it, and didn't break 2. I tried several cases of really pulling hard to separate some straps I connected with it and could not. Decided it was good enough to use but with further testing once it's assembled.


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Thanks for the read. I may order some Tera 40 to compare before doing another. I looked for it briefly on your word when I'd run out before, after I already ordered more of what I started with, but could only find it at JoAnn where the naming changes confused me. I saw a gutermann rep clarify the naming later, but then my local store didn't have it in.

I can't find the original recommendation now, but I found the link to the C&C thread I used on a hammock or climbing site.

This is it the thread: COATS & CLARK Extra Strong Upholstery Thread, 150-Yard, Chona Brown https://www.amazon.com/dp/B001EL5U0E/ref=cm_sw_r_cp_apa_.urRAb9Q1DYQT

I don't know how they're tested for strength or stretch officially. I know I had to give a very solid tug to break 1 thread of it, and didn't break 2. I tried several cases of really pulling hard to separate some straps I connected with it and could not. Decided it was good enough to use but with further testing once it's assembled.


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I posted links to the Gutermann threads in the DIY SEWING MACHINE thread. I just want to make sure you guys are SAFE! I can’t control your stitch quality/count, but I can try to steer you toward materials that are tried and true and are backed by good research.






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@ckossuth, did you have a particular tensioner/adjuster/ladderloc that you used in the side adjustment straps?

Saturday I got to sit in my saddle for the first time, and the cheap backpack plastic tensioners I'd recycled snapped when I tightened them. I have found metal ones on MilSpecMonkey ( http://milspecmonkey.com/store/hardware-diy/467-itw-gtll-1-ladderloc.html ) but I figured I'd check first.

Gracias
 
@ckossuth, did you have a particular tensioner/adjuster/ladderloc that you used in the side adjustment straps?

Saturday I got to sit in my saddle for the first time, and the cheap backpack plastic tensioners I'd recycled snapped when I tightened them. I have found metal ones on MilSpecMonkey ( http://milspecmonkey.com/store/hardware-diy/467-itw-gtll-1-ladderloc.html ) but I figured I'd check first.

Gracias

I canibalized mine off of an old compression duffle I tore apart. They are heavy duty plastic but not sure from where. You might try Hudson Supply in Canada or just go with the metal ones.
 
@JBDaddy where is that saddle bro!!


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Haha, sitting on my dining room table.

I had to fly to DC Sunday for meetings all day Monday, so lost 2 days of tinkering. Saturday I tested it out and found the plastic tensioners I used... wanting.

But my gutermann thread came today, I've got 4 stronger tensioners and 2 Ropeman 1s in the mail to me this week, and Saturday I'm going out scouting with my son, where we'll try out the helium sticks, saddle and mapping apps.

I'll make sure we get some pictures for ya
ladderlocks-1-metal-milspec.jpg

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@JBDaddy where is that saddle bro!!


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So... Just tested the gutermann thread in my highly scientific "wrap each end around a pencil and pull them apart" test... The coats is stronger. :/

3 different times, and my wife tried it too and agreed. Is this the right stuff?
970be6e9fcea02277ad786823a383e01.jpg


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So... Just tested the gutermann thread in my highly scientific "wrap each end around a pencil and pull them apart" test... The coats is stronger. :/

3 different times, and my wife tried it too and agreed. Is this the right stuff?
970be6e9fcea02277ad786823a383e01.jpg


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Interesting....I need to try that with the Poly I picked up from the thread exchange.
 
So... Just tested the gutermann thread in my highly scientific "wrap each end around a pencil and pull them apart" test... The coats is stronger. :/

3 different times, and my wife tried it too and agreed. Is this the right stuff?
970be6e9fcea02277ad786823a383e01.jpg


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It looks right but I’ve never seen that kind of label before. Did you get it from Rockywoods? Here’s the label on mine.

600ebd09141268816e77e440e56e46ba.jpg



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Nylon

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There’s your answer. Nylon thread is stronger than polyester but as a general rule it is not used on any outdoor gear. It breakdown over time in an outdoor environment. It also doesn’t have near the abrasion resistance that polyester has.

There seems to be two separate camps in regards to using nylon thread on outdoor gear. On seller says to use it only on inside projects and another says it can be.

All I know is companies like Kifaru, Seek Outside, Hammock Gear, and the like only use polyester thread because of the combination of strength, UV resistance, abrasion resistance, and it’s resistance to break down over time.

From what I have researched (and my own personal experience) nylon is absolutely stronger strand for strand than polyester but that’s about it.

I’m not going to knock what you’re using as I haven’t used that exact thread. I highly recommend doing your own research on everything I just stated. I want you to be successful in your projects but this particular project is literally supporting your life.


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There’s your answer. Nylon thread is stronger than polyester but as a general rule it is not used on any outdoor gear. It breakdown over time in an outdoor environment. It also doesn’t have near the abrasion resistance that polyester has.

There seems to be two separate camps in regards to using nylon thread on outdoor gear. On seller says to use it only on inside projects and another says it can be.

All I know is companies like Kifaru, Seek Outside, Hammock Gear, and the like only use polyester thread because of the combination of strength, UV resistance, abrasion resistance, and it’s resistance to break down over time.

From what I have researched (and my own personal experience) nylon is absolutely stronger strand for strand than polyester but that’s about it.

I’m not going to knock what you’re using as I haven’t used that exact thread. I highly recommend doing your own research on everything I just stated. I want you to be successful in your projects but this particular project is literally supporting your life.


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Thanks for the guidance. One saddle is already sewn up, but as I get started on number 2 I'll do some more webbing tests and switch if it's working well. I'll be watching for frays and pulling in both versions for a long time to come and replacing either if it starts looking iffy

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Thanks for the guidance. One saddle is already sewn up, but as I get started on number 2 I'll do some more webbing tests and switch if it's working well. I'll be watching for frays and pulling in both versions for a long time to come and replacing either if it starts looking iffy

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I don’t know what kind of work you do or what kind of shape you’re hands are in, but if they are rough and you lightly drag your fingers across the nylon thread sideways (like a guitar string) you will likely feel the nylon fibers snagging and catching on them. You might even pull a few fibers loose. This is bad. That is very indicative of a thread that has little to no abrasion resistance. Like I said though, I’m not familiar with what you are using. It my have some kind of bonding on it to prevent that.


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I don’t know what kind of work you do or what kind of shape you’re hands are in, but if they are rough and you lightly drag your fingers across the nylon thread sideways (like a guitar string) you will likely feel the nylon fibers snagging and catching on them. You might even pull a few fibers loose. This is bad. That is very indicative of a thread that has little to no abrasion resistance. Like I said though, I’m not familiar with what you are using. It my have some kind of bonding on it to prevent that.


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It is a bonded 3 strand thread. I've picked my nails hard across it without any fraying so far, but I'll be working at it all summer, with more test sits and bouncing and pushing against it before season starts.


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