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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