Don West Lost in Space (netflix 2018) space suit.

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Danlex9

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So as the title suggests, this is my thread on my Lost in Space space suit. I am currently in the process of recreating the orange Don West suit to the best of my abilities with available materials. So here’s the show suit and let’s dive in. Be gentle this is my first major sewing project and I’m learning as I go.
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Danlex9

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First off materials!
For the normal looking cloth parts I wanted something soft and for the hexagon pattern parts I wanted something stiff. I chose a flannel for the soft sides, and a 6 oz duck canvas and both oranges are a near perfect match. Now when it comes to the stripe portions that go down the sides of the torso I chose a brighter material, I wanted them to stand out more much like the blue space suits worn by colonist families on the show. For that I found a cotton twill and since that’s so thin I back it with some flannel. Zipper wear is fairly basic except the black one is a large parka jacket zipper for attaching the jacket to the pants.
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Danlex9

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As for texturing the material I’m using my cricut explore to the max. Created my own hexagon and zigzag patterns in 1ftX2ft sheets, the largest size that the machine will cut. These are cut out of heat transfer vinyl that I have ironed onto my materials. So far this was the hardest part of the project, I had to crank the cricut up to card stock so that it cut the hex dots completely free from the sheets as each sheet had around 9k dots within them. Weeding 15 sheets at 9k a sheet would have set my brain to outer space and I would have never returned, and worse the space suit wouldn’t even be done for me to take along!
The last photo is: a fresh cut sheet using new blade and card stock high settings(left), the hexagon dots stuck to the cricut mat(center), a sheet cut with a dull blade with 98% dots still attached(right).
That is my method of “auto weeding”, I can now scrape the dots off using a metal putty knife and a vacuum for easy clean up and cut again.

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Danlex9

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For the padded portions I’m using 1/4 inch batting and 1/2 cushion foam. For the padded forearms I actually had to watch a YouTube video on how to for it and my practice run came out okay. My practice run for the body armor padding went even better.
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Danlex9

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For the banding around knees and elbows I did a practice run using 1/2” black bias tape, 1/4” orange bias tape, and silver bungee cord.
Based on the Will Robinson suit I ran into in NYCC I could see the cording is zig zag stitched and once I learned how to do that I gave it a shot. When I make this over for the suit I will actually use strips of the same orange htv I used for the hex pattern which I will iron onto the black bias tape. I believe this will give a more accurate look.
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Danlex9

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Now for the meat! The suit itself. In order to make the pants I painstakingly took apart an old pair of carpenter work pants that already fit me the way I needed the space pants to fit and used those parts to make a muslin version that I could then draw the space suit parts onto and then cut apart to make new patterns for the space pants and boom there they were.
For the jacket I used a mcCalls pattern to make a muslin coat, trimmed that to size and then drew the new patterns just like the pants.

I made new paper patterns from these labeling which fabric should be used, which texture, and numbered the pieces.
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Danlex9

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It was at this point I decided which fabric to use for the shoulders and joints. Turned out to be pleated pleather cosplay fabric from my local joanns. This was after ordering server all swatches from around the world, literally I have two from Germany some from China and a few from Australia.
OF COURSE I REALIZE ITS NOT ORANGE HAHAHA.
Cut out the pieces I needed and painted with angelus leather paints.
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Danlex9

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For the “quilted” sections like the abs lower back and collar I’m using the flannel backed with the 1/4” batting. Did my best to count out the lines in my reference images to figure out widths. The back section was then sewn to a piece of the painted pleated pleather and is ready for the rest of the jacket.
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Danlex9

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Time for pants! I’ve been using the patterns I made to chop everything up and I’ve been assembling the pants inseam out. This was so I could more easily sew the zipper I to place and there an inch and a half wide band joining the two sides of the pants and it just felt easier to sew all that together before the outside of the pants bunched everything together.
At this point you can see the brightness of the stripes so I include a dirty quick photoshop(left side image) of what I’m going for. Again if I change my mind I can color match them with the angelus leather paint.
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Danlex9

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Couldn’t find piping in the right orange and I didn’t want to paint it so I cut one inch strips of the flannel and sewed some orange bungee into it and used that. I did however have to paint two short pieces of that cord for the face of the knees. Silver cord is zigzag stitched to the knees. Pants are coming together!!!
I’m super happy so far.
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Danlex9

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First leg! In order to attach the knee/shin portion I had to sew the cord/banding on first, fold it up, pin the knee into place, stitch together, flip right side out and flip the cord/banding back down to cover the seam.
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Lowbeer

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I've always admired the perfect combination of complexity and practicality the suits on that show seem to pull off. I'd love to make one myself some day.

This is crazy good work! You sure this is your first time with a sewing project like this? ;)
 

Danlex9

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I've always admired the perfect combination of complexity and practicality the suits on that show seem to pull off. I'd love to make one myself some day.

This is crazy good work! You sure this is your first time with a sewing project like this? ;)
Made one of Adam Savages EDC bags and a Dr Disrespect vest first. Because an orange space suit is a natural progression from those things
 

Danlex9

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PANTS, I have made pants. Currently cleaning the waistline and ankles. Also want to put a clasp at the top of the zipper cover.
On to the harness!!!
Also ordered a bunch of cobra buckle knockoffs from AliExpress, they are not exact and need to be painted but want I paid for 8 is the same as buying 2 of the real thing. Pretty sure half the shows budget went into the cobra buckles, I mean look at Don I can see 8 on just the front of his pants.
I
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Pocko

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This is really awesome. Great idea using the Cricut to make the textured fabric. Just a quick question. Does that thickness setting go straight through the HTV including the backing? I guess that's not a problem as the whole thing is a single piece?
 

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Danlex9

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This is really awesome. Great idea using the Cricut to make the textured fabric. Just a quick question. Does that thickness setting go straight through the HTV including the backing? I guess that's not a problem as the whole thing is a single piece?
Yes it’s cut down to the mat but doesn’t cut the mat. And yes it’s not a problem because it’s a full sheet. It actually make the iron on process a lot easier, I’m guessing the heat can get to the material faster because of the through holes.
 

Danlex9

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Started the harness, basically winging it. Figuring measurements based on using 2” grey webbing as the main belt and 1” webbing for the leg loops.
Using grey 3D spacer mesh ordered from AliExpress. Basic black knit for body. The black/orange loops are bias tape sewn closed with orange htv ironed on top.
To add the accent lines to the webbing I used this bias tape presser foot to keep the lines even and stitched it using thick quilting thread.
Still have to repaint or strip the paint on the mock cobra buckles.

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Danlex9

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Made some quick changes to the belt after looking back at my reference images. Made the rear rings for the leg loop detachable with Velcro so it’s easier to sew everything together with out the whole harness being stuck under my sewing machine. Plus the grey soon to be comic con snack pocket
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