Apollo 11 nasa lunar suit

Lear60man

Master Member
RPF PREMIUM MEMBER
Once again Halloween snuck up on me without time to make a killer costume. I was watching in awe at Darkjedi1500's home made Apollo suit when it hit me.....I wanna be an astronaut. Two things were against me, My crushing work schedule and I dont know how to sew (rectified since then). I have always made my costumes and purchasing a costume was like cheating. I saw a youtube vid of Adam Savage wearing his Apollo suit and the upgrades he made. That was the last bit of inspiration I needed. If I could find a suit that is 70% workable for under $2k.....Ill figure out something.

In Dark Jedi's thread, another member linked a couple of Apollo suit makers on the web. A couple of problems, Either they were $10,000 or they were $2500 and grossly inaccurate or cheap, ugly and cheap. The $10k suits were out due to delivery times and, well, they were 10 grand. I found a suit on Ebay for $1,600 with a month lead time. They also sell a 'Museum' quality Apollo suit for $8,000. I emailed the seller and told them I wanted the museum quality fabric, metal ab fittings / neck ring, commander stripes and dual visors for the helmet. It was lacking the detail of the $8k suit but I felt I could make it work.

It came in last Friday. This is a shot of it out of the box. I was happy, not ecstatic and not disappointing.....just happy. The material is great and light weight. They included an under suit to bulk it up. I have to bulk it up more to get that puffy look. The patches were a faded color and printed on white denim (im assuming the same material the budget suit is made from). It lacked a ton of detail, but again, this isnt the $8k Museum suit.



Lets get to work. I started to add the abdomen Velcro. Between the Velcro strips are metal snaps on a Teflon disk on a fabric 1.25 inch square. The fabric square had me stumped....I couldnt continue.

Did I mention I cant sew? I bought the wife an industrial Singer sewing machine for her Bday last week. I busted it out, looked at the diagram printed on the machine, hand wound a bobbin (later I found out there is an auto winder on top........all sewing machines have them). An hour later, I had 8 1.25 inch squares!!!!!! The first one was a mess. 2-7 no problem.



I downloaded era correct NASA and Apollo 11 mission patches (originals were printed on 'Beta' cloth and hand sewn on). And printed them on inkjet printer white fabric.....and hand sewed them on.



The back pack or PLSS (Personal Life Support System) that came with the suit was......horrible. Two blocks of foam covered by fabric with some shoulder straps. Everything about it was wrong. Great for a costume party, not so good for the RPF. This is it straight out of the box:



So I picked up some 1/2 plumbing pipe, a million fittings, rivits and 5 yard signs made out of congregated sintra from Home Depot.
Wrote down some measurements from various space sites that listed the dimensions and went to town.



PVC frame, yard sign surfaces. Covered it with quilting batting to give it a soft puffy feel. Added a hand hold (?) in the center ( Im calling it a hand hold because the real ones have one. Its basically a cutout in the center like the place you put your soap in the shower. Maybe Ill put a bar of soap in it for Halloween). Once the spray on glue dried to keep the batting on, I covered the edges in reflective metal tape. Dont know why, but it made sense. I made patterns for the PLSS and used some spare fabric I ordered with the suit. I reused the back panel as it already had the shoulder straps attached. I made a correct PLSS checklist, NASA logo and Name plate on the computer and printed them out on fabric. Sewed the edges and hot glued them down. They look like they are sewn on. Finished with some more velcro. The PLSS cover slides on over the top and velcros up at the bottom, similar to the originals.

This is the finished product:





Picked up a replica Omega Speedmaster with a replica NASA strap made by some bloke in the UK.



The stock gloves used blue dishwashing gloves for the blue fingertips........no good. Went to Home Depot and picked up some gloves that had the fattest-roundest fingers I could find. Dipped the fingers in blue Plasti-dip and presto chango.....moon gloves. The silver material is Ironing board pad material.......its even heat resistant! Bonus.



This is where it is at tonight. I will start weathering it tomorrow. I need to add some more puffiness to it and a micro climate vest. I might add a tinkle hole or just do what the astronauts did, it all depends.



Stay tuned, more to follow. I have to go to Chicago Thurs-Sat so no costume progress but Ill try to pump out some more progress in the next two days.
 
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Wow that is epic! It never crossed my mind about going as a classic apollo ara astronaut.....or even a modern day one. I think I might use this idea next year for our local zombie pub crawl and go as a zombie astronaut. Im sure everyone will be over the moon (ha) about your costume!
 
I saw one of these suits a couple of years ago and was seriously unimpressed. You really turned it around, good job!
Just curious, how hot is it to wear this thing? I know DarkJedi's amazing A7-series suit build has a fan to vent the heat out.
 
I saw one of these suits a couple of years ago and was seriously unimpressed. You really turned it around, good job!
Just curious, how hot is it to wear this thing? I know DarkJedi's amazing A7-series suit build has a fan to vent the heat out.

Like I said, there are a couple suits out there in the $1,000-$4,000 range that look horrible to the trained eye. Common fails are: Using cheap / incorrect fabric like white denim or canvas, cheap helmet or starting with the wrong base......like using a pair of overalls. If a company is going to charge this kind of money for a replica, its not hard to fix these mistakes. It takes just as much work to do something right..... just a little more effort. To truly get an accurate NASA suit, you will spend $10k plus and there are only two companies that make them, but they will be accurate to the eye.

To answer your question about the heat, let me digress. I opted for a high quality fabric. The problem with this fabric is the thickness. Its fairly thin, thinner than denim. But its coated with some sort of rip stop / semi shiny coating for the correct look. When you put it on, it doesnt have the 'puffyniess' of the real suits because its not 25 layers of material including the under suit bladder. I ordered a quilted jumpsuit to wear underneath to give it bulk, that is what I am wearing in the last pic. I dont like the undersuit because I feel its not bulky enough and doesnt fit well. Soooo, I will be using a medium weight winter coat and sew on the leg portion of the supplied undersuit.

I will be using a cooling vest on my torso. Option A is a Nike Precool vest. Its a vest with a bunch of little packets filled with freezable gel. You freeze it and wear it. Option B is to sew in pockets to the inside of the winter jacket torso and insert off the shelf lunch box reusable ice packs.

In the future I can easily rebuild the PLSS to incorporate a Microclimate system. The microclimate system is basically a motorcycle battery that powers a small fountain pump hooked up to a series of tubes around the torso. There are ready made systems for a couple hundred bucks. There is a small ice chest that houses the pump and some ice water. The motor pumps the cold water into the torso tubes where your body warms up the water. The warm water returns to the Ice chest chamber where it is cooled by the ice. And repeat. When the ice melts, ask the bartender for a refill.........because of course you will be at the bar.

But for this Halloween Im going with the quick and dirty ice pack vest method because yes.....its warm. Very warm.

Ill put up some more progress shots tonight.
 
It never occured to me that someone could turn one of these around so effectively. I'd never try to make one from sratch but you are giving me some ideas on maybe trying something similar.
To truly get an accurate NASA suit, you will spend $10k plus and there are only two companies that make them, but they will be accurate to the eye.
Yeah, I've seen one of the Global Effects ones, I know what you mean there. They do amazing work, and they tried for a few real-life contracts to make real pressure suits for NASA in the past, and have provided training suits and program-used mockups for them. I wish I had the money to have them make a A7L and an ACES suit for me, but that would cost more than a good new car...
Having handled three real-life A7L suits, one of which has been on the lunar surface (I can't name which one because the person who let me handle it probably would get in trouble as it was recently), I have a true appreciation for these suits and would never attempt to make a replica because I just don't have the skills to do it right.
When you put it on, it doesnt have the 'puffyniess' of the real suits because its not 25 layers of material including the under suit bladder.
Well, it also isn't pressurized, which is really where a lot of puffiness comes from, but I get your point.
You probably know this but it's funny how few people do, that the 'white' part on a A7-series EVA suit was actually just the outer cover, it provided no protection from the vaccum of space at all. The beta fabric white outer covering provided other types of protection, though (against fire in the cockpit and minor micrometeorite impact) but really, the 'space suit' was underneath the white part.
 
P51,
Guard Lee is the other one I was thinking of.

As long as the base suit was workable, I was game. There are a bunch of things that are inaccurate plus there seems to bee a million pictures on the web with subtle differences in various suits from mission to mission making it more complicated to get a good replica. I kind of borrowed from various Apollo mission suits. For example, I added a sample bag on the right shin. Not Apollo 11 accurate but looks NASA correct. I also added the commander stripes and pressure relief ball ( I think thats what it is.) Little things that are making a huge difference to make it more realistic, just not mission specific.

Dont get me wrong, Im happy with the base suit how it came from the seller. I think it had the perfect mix of accurate VS price. For me, It was the best out there that didnt have any fatal flaws. I dont think I can find a better fabric. I did buy some Tyvec, and duck twill. The PLSS is covered with the duck twill. Im saving the left over half yard for the cover on a Space Shuttle EMU helmet rig. Something that pops on and pops off. Super fine thread fiberglass might be the ultimate but I dont know how easy it is to work with.

The thing Im on the fence about is the color of the velcro on the abdomen.......beige or white? Ive seen pictures of both. And not just dirty white Velcro....its beige.


I think I can get it to 85% Guard Lee after more time and fabrication. Learning to sew last week was a big help.

Update pictures after dinner.
 
Guard Lee is the other one I was thinking of.
Oh yeah, I keep forgetting they make suits. I've seen some of the full scale craft they make, like the Explorer orbiter that used to be at Kennedy but is now at Houston. That thing was amazing!
The thing Im on the fence about is the color of the velcro on the abdomen.......beige or white? Ive seen pictures of both. And not just dirty white Velcro....its beige.
Actually, it should be white, that stuff yellows with age. I've talked with several people at the Smithsonian about how the suits have aged and I heard that anything yellow was originally white. If you don't have this book, I strong recommend it, it's an amazing book on the preservation of the pre-shuttle-era space suits: Spacesuits: The Smithsonian National Air and Space Museum Collection: Amanda Young, Mark Avino, Allan Needell, Thomas P. Stafford: 9781576874981: Amazon.com: Books
 
Thanks P51..Ordered!!!

Added a sample (Astronaut freeze Dried Ice cream pouch to the right shin and added some pockets to the left thigh pocket.


Added an upper left forearm sunglasses pocket and Armstrong checklist on the left glove. This is the Omega Replica and strap.



Current shot. I am going to add another couple of hoses / control cables next week. The boots are finished as well. Thanks again DarkJedi for your foam gluegun method. I bought some Converse Allstars and foamed them up from the inside of the boot shell......comfy!!!!!!! I couldnt bring myself to weather it. Im sure time will do that on its own.



Im thinking I still need to fill it out some more and work on the cooling vest. Next week.
 
Good Lord! This thread is on page 7 after a day! This needs to be moved to the Showcase forum!

Again great work on the suit Christian!

I know what you mean about "not" being able to weather the suit, however I think you should go for it (albeit "lightly") as it would really bring out the details!

I'm going to add some light weathering to my own suit.


PS (and maybe a bit off topic) on the control box, what the heck does MOM stand for? I could never figure it out. :lol


Levin
 
I got some shots of a real PLSS over the weekend, detatched from any suit. I e-mailed you directly but never heard anything back. PM me if you want to see the shots, as you hardly ever see what a PLSS looks like from the front as the suit is always in the way in photos...
 
P51, Ill PM you my email addy. I might have an old one still listed with the RPF. BUT thanks big time!!!

Speaking of PLSS's.................

The top portion of the PLSS was bugging the heck out of me. It was undersized and to rectangular. I scratch made another one using the same method as the lower PLSS minus the pipe frame. Its light weight and rigid. From looking at the hundreds of pics online, you get a sense of how the originals were put together. Hopefully mine is close from a visual standpoint.

Refer the the 4th photo from the top, that is the PLSS that came with the suit. Nothing but the hose connectors remain.



Top view:



This is behind the Astronauts head.



One day Ill rework the antenna, the warning light and add a pressure gauge. But for all intents and purposes, its done.

I used a hockey goalie check pad/shirt as the under garment. I cut out some of the chest pads to make pockets for reusable Ice packs. Why you ask? Because this thing is beyond hot when its all zipped up. With the old under suit I was at critical temps within ten minutes, so I ditched it. The Ice pack hockey armor bulks out the torso and is now chill.

So here is a selfie. The Apollo purists will not be happy. I tried to hook up a Shuttle EMU light rig. I ended up looking like the Flying Nun. Way over scaled. Time permitting, I still might to scale it down and see if it looks decent. The 'Bonnet' is ok, its just the light pods and triangle things behind them that are throwing me off. Besides, the flashlights are like a brazillion lumens. Great for space, not so great for a crowded bar.

 
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