Update time on the stripes - here we go!
After some deliberation, I decided to cut the entire stripe 'patch' from the Cordura and inset the stripes. I traced the piece out on the back (coated) side with silver sharpie and, leaving a large amount of space on the outside (making it much easier to handle), I cut out the stripe areas and the stripes and inset them one at a time. For a hint at the nerve-searing scale I was working with, the first pic is taken next to a sharpie.
The second image above is the bottom stripe from the back showing how the blue was cut to the corners through the seam allowance and the angles were sewn. When doing this kind of angle work (which I do quite often), it's very helpful if you can trace the stitching lines onto the pieces. In the first image above, you can see the lines on the blue and the stripe where the corners and the finished lines should match up. This way you can carefully keep an eye on all of your points and lines as you're constructing the piece.
When you don't have the option of tracing out the lines or using chalk or markers to mark dots on the fabric, tailors' tacks are invaluable. If you're not familiar with that term, a tailors' tack is a single hand stitch that marks a point on the fabric as a guide - then, you just take the thread out when you're done. Here's a pic to illustrate:
With the three stripe pieces inset into the blue, I then needed to finish the edges. I trimmed all the silver vinyl to an even 1/4" around the edges and trimmed it across the internal stripe areas so it would lay flush and not overlap. Then, since I didn't want any other stitching to show on these pieces, I turned to every costumers' most trusted friend and the single item that no shop, whatever the size or budget, can function without.
Once the edges were glued and trimmed, I added the magnets. These are neodymium or 'rare earth' magnets and are wicked strong. I used Loctite to secure them to the back of the 'patch'. The entire patch will be finished with Cordura contact cemented down to both finish the piece and also to make sure the magnets don't pop off the back.
I lined up the 'patch' to the chest, pinned it on and turned it over so that I could match the magnets on the inside of the jacket. Here are a couple of images of the new & improved stripes on the chest. This version looks much more sleek and 'seamless' and matches the look of the shoulders much better than the first version. Yay progress!
Last week, I decided to do a test run of the pieces together to see how they moved and fit together. Overall, they fit together really well, move really well and are quite comfortable. However, I noticed that, if he tries to pose in certain ways (really extreme poses, like the shield-over-the-head), the mesh 'tank' top on the torso will show. Bad. So, I'm going to revamp this area with the blue spandex and make it more of a 't-shirt' fit than a 'tank'. That way, it will all blend together no matter how he moves or which torso he's wearing.
That will be the next step as well as finishing the pants. After that, it's all about accessories! Stay tuned...