I found this site and started research and wanted to make a pack. After nearly constant research for years, I finally started my own styrene scratch build in October 2015. That is still very much underway and you can watch my progress in the build thread link in my signature.
With the pack going so well it's been eating at me that I still only have my piss flight suit imitation. That has changed as of today!
Locally sourced for $59.99 is a non used Carter Industries Nomex CWU-27/P fight suit!
I originally went to an army surplus store closer to our apartment with measurements in hand. Chest:43", hips:43-44", inseam:30", arms 23". I'm just under 6' at 5' 11.5" and 210lbs. I tried on a 42L as sizing charts say it should fit perfectly. It was a bit tight on my chest and real tight on my gut. An employee brought out a 44R, it was pretty nice on the chest but tight on the gut. Not loose at all. He said the next size up they had in stock was a 48R and said it'd probably be way too big even for the baggy look I was going after. He gave me his card and said to call back in a couple days so he could check the warehouse for a 46R. I left and had another store just 15 min further away to check out. In Chicago that's not very far at all.
This next store had several in 46, some in 44 and 40, but only in S and up to 46. I tried it on and holy crap, it seemed perfect! I tried a 48L blue service overall, and it's was really nice in the gut, but the chest and back was like a deflated balloon. Not sure if that would translate differently to the flight suit as these were overalls. But seemed to scale the same. I put the 46S back on and sat down. In the old Rithco, sitting was a strategic and careful endeavor! The boys were always in real danger lol. This Nomex suit was even more comfortable sitting! I stretched around and did all kinds of maneuvers. Seemed good.
I was going back and forth in my mind if I should go back to the original store and try on the 48R, but staring at myself in the mirror and pulling up reference shots on my phone, I started to really like what I had on. So I bought it! Woo!
Rothco on left with patches, Nomex on right. To me it's night and day! The color of the Nomex is such a thing of beauty!
Pissed my pants? Looks like I took a golden shower! :/ The sleeves were always too long and the pant legs as well. This is the compromise I had to make to be able to breath and walk without a wedgie. Never liked how low the chest pockets were either. This an XL.
That's so much better! Nomex goodness! I like the lighting here as you can see different castings from the indoor lighting and the overcast outdoor lighting spilling into it.
What do you all think? Did I make the right size decision? Still can't believe at almost 6', 210 pounds, broad shoulders that a 46S fit perfectly. All cuffs are ideal!
Now it's time to transfer patches and get my leg house connector on. Maybe I'll sand the zippers, but they look pretty nice black.
"Let's just not get bogged down in print tolerances, as spending six years cutting a perfect pack is all blown away once the thickness of the PAINT is introduced! hahaha" - johnnyace_pi
0.125" Styrene Proton Pack Scatch Build Thread
Rothco to Nomex Uniform Upgrade Thread