The buckles are the thing I’d change the most on my kestrel. Why not have light, small, plastic buckles on the legs like the alpine bod harness. Could do away with the linemans loops too and really lighten the whole system up.
Y’all do have some skills though. They look fantastic!
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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