6'3" 36" pants 240lbs (I need to work on this number) and I ordered a size 2. From past experience when on the edge of sizing I have always found it to be beneficial to go a size up. In this instance I figured that having the extra material will put the pressure points in front of my hips, not on them, and as seasons progress you tend to add bulk in either layers, fluff, or both. From what I have been seeing on this forum, I feel confident that I have made the correct choice in size. It is highly unlikely I will actually get to hunt with my kestrel this season (Jan 31 here in NJ) but that gives me all spring and summer to dial in a climbing method, practice set up and shooting, and figure out my tether adjustments. I am checking this forum several times a week, if not twice a day, and the info that is here is gold. Good luck to you and it seems that you will be more happy with the bigger size.
Mike
Mike