Zam Body Suit

Ok here we go to start a new topic for posting to the body suit info. The Vest and Bodysuit part had gotten long and well time to shorten it up some. So all future posts to it here please. I would like to take this chance to thank Zam I Am for all she has done and for listening to the suggestions of others like myself. Between the group of us a very authentic Body suit may come out of this for those involved.

"here here"

Why tanks! :o -> seriously, the other thread really was long, plus, my leg was stretching the screen to far to the right.
eek!I just realized that people all over the web saw my leg close to 1500 times.

Here's looking forward to the fruits of our labors!
Scriptie & Ben

Wookie,
Can you give us that info on lycra dying, like which manufacterer/company dyes the lycra and how much did they want to charge etc. We have about 48-56 yards to contend with if we decide to go with a white lycra and dye it to match DCB's pantone. I want to see how much extra cost this would be since it's amongst a whole group of people.

--------------------------------------------------------
Wow, I just called one company and they want an extra minimum order of $300 if we custome dye lycra. ouch. I'm just gonna keep on asking lycra companies to send me swatches, hopefully we can get a match.

It was Glomex that said they could dyematch it.

Thanks wook, pm sent. How can I call them, do you have the #?

Glomex:
800-882-9088

Contact: Paula O'Neill

I think she got a bit frustrated with me, so I'm not sure how much help she will be.

Dan

oOPS, i posted my stuff under the wrong thread. Be sure to read about dcb's lycra color matching under the "our fearless moderator" thread.

I'm just imagining a gray suit with me trying to get people to shine purple light filters in my direction as I walk by. This is really a color problem. I wonder if the people at ILM purposely did this just to throw us off...

Ok, here's the deal with the color, some people have pointedly made it clear that they want it dyed to the color that dcb is comming back from aussie with for the lycra, so, of course, it would cost more. I will be calling the two companies to find out how much exactly it would be to dye it. If I have swatches that are already that color, then that means cheaper cost for us, if not, then I think that-to not dye- the lycra would be a real misfortunate situation, ie, sacrificing authenticity for cost. I think most of us agree, voting on color would be a problem, and if we weren't going to be authentic about it, then why get the neoprene in the first place, right? So, the process for how this bodysuit project will go down, is, dcb comes back with the color, I try to match it with some of the swatches that I have, if it isn't close, then I will buy white nylon-lycra from a company and ship it off to have it dyed to dcb's color match. Then, after that it will be shipped to the neoprene company to be laminated.
Question for all of those in on this project: Matte-finish or shiny, and 2-way or 4 way stretch? (i will ask the neoprene company if this affects the bonding process) I know for sure that 2-way is cheaper, but, if we can't move in the suit, then it's not worth it. And, for those who want to join in to purchase the bodysuit fabric project, PM me before I order the lycra. I will quote an approximate price after dcb gets me that color.

Thanks wook for the company PHN#! They helped me out lots, they are going to ship samples to me on monday. It's a lot nicer to work with one company instead of 3. People in the bulk fabric purchase project-- if anyone has anymore imput as to whether the type of lycra has a specific finish, I seem to be running into the fact that it's probably going to be a nylon-lycra combo like 88% nylon 12% lycra laminated on neoprene. They have different thicknesses of neoprene too. 0.5mm on up. So, if any of yall have a change in thickness preference, let me know. The less thick, the cheaper, but we still want enough for a "bulk"+correct leg-crease look. The picture from the other company that i had dcb post earlier, is a lot larger thickness, either 1/16th inch or 1/8th inch. So, we could go afford to go smaller. The lady at the company also said that mostly, it would be a 2-way stretch costume. She said she worked on movie costumes before and most use 2-way stretch. It's also more cost effective. She said we might also consider having it double laminated with some cheap nylon on the inside so that we don't smell like a rubbery batman after wearing it. Just some thoughts. Anyone else have any?

sounds like a plan, Zam I Am

sorry :p


Cal

Well I am ll for thinner the better. A word to the wise since I was a scuba diver that Neoprene does build and trap body heat. so the thinner it is the longer we stay cool in it. Also if we do a lycra on both sides go with black or a color they have readily advaliable for the back side. Makes it cheeper for us if they do not have to change things up a lot on their equipment.

so are you now looking at fully made costumes, or still bulk material that we would need someone qualified to assemble into a suit?

-cris

Well, currently, just the lycra-neoprene bulk material. We can't buy from lycra laminated neoprene manufacterers unless we meet a specific bulk quantities/or $$, so I am bulk ordering for those who pm'ed me. If people want to have a body suit made out of the lycra-neoprene material, my seamstress is offering up her services. She won't have time until after holloween to do the suits. (I can't even have the bulk material ready until after then anyway.) I am giving my seamstress all the posts regarding making the suit. Welt seams and all. Still waiting on DCB and swatches to compare lycra color that is supposed to be laminated to the neoprene.

Cris, does renaissance dancewear still have the pattern for Kim's suit? If we could get a copy, That could save my seamstress lots of time and everyone some money(for those who want a suit made by her.)

Regressen, Scuba-dooby doo! So, do you think it's a good thing to have it laminated on both sides? Oh, by the way, this two-way stretch neoprene is not the neoprene for swimming in, but still a hot'n'sweaty container for us. It's the less expensive type of neoprene.I should ask the company how we could wash the suit.

Moncal, what are you sorry for? :p

they probably do, but I'm not sure they'd give it away.

I guess you could always ask them. They'd probably remember Kim since they had such a hard time matching the color.

-cris

Quote:Moncal, what are you sorry for? :p

Oh, I'm not really
I was just playing with rhyme

All joking aside, I'm looking forward to what you come up with.

Good luck with it.

Well from what I know all Neoprene is a rubber based material. Yes laminated on both sides is best. As to washing it I would say we will either have to dry clean or warm wash and hang dry just like a wet suit. my wetsuit I would toss inthe dryer to cause it to shrink some as I wanted a tighter fit.

Moncal--
Bust'in rhymes eh? Heheh Need to form the starwars rap group alliance...
the perpetrator, was he who became vader
but little did he know that sideous, the mysterious
hired two hoods called jango and zam, who i am,
to kill at the senator, hard core
she had the bling bling, and anakin be her thing,
the story's still movin, the jedi still grov'in
but still gotta pay the fee, and wait for episode III

Peace out! (Gotta spread the cheeze..)

Zam I Am, you're killing me. I'd give credits to see you rap that in costume!!

Yeah, I can just imagine me a-chinese starwars rapping fly-girl in de house!

"your republic credits are no good here..."

Kim 'n cris, they wouldn't sell the pattern to me. Darn... Oh well, guess I gotta have my seamstress draw up one. Renaissance dancewear said that we needed a 4 way stretch material in order to make this. I have a feeling, we need our bulk order to have 4-way stretch material, or we'd have to be ordering more yardage.

i made up a trial pair of pants in a 2 way stretch (haven't made the top yet) but the pants turned out very well (stretch wise, anyway- the pattern still needs a little tweaking) then again, i don't have to contend with too many curves..... LOL. I'll play with it...

~MaryAnne

Wow, blue-that's awesome, seamstress in de house! Yo yo yo! ok, I'll stop it now I'm annoying myself with the-almost jar-jar ebonics. Can't stop the Jenny lopez songs in my head either. If it worked out really well, with just two-way stretch, then we'll get that. less expensive the better. I think that if people wanted a unitard, then 4-way stretch would be the way to go, but since I think more people want a two piece, for costume wearing reasons, 2-way stretch is the way to go. Blue informed me that you have to have the 2-way stretch laying horizontally for the pants.

Once those swatches go out, y'all in the fabric project will really start understanding all this talk about thickness. I bought a bottle warmer from the dollar store just to understand the foam core concept awhile ago. Sorry the swatches will be small, since I only have just enuff to go around. Please pm me your addresses, for those who want samples. I will need two weeks before they go out, after dcb gives me the "most accurate color" swatch. I still have two companies who might do a color match.

The double laminated neoprene swatches will be unavailable to view online this week, because my hubby's comp is down for the week, so, we have to buy another comp and do necessary upgrades. For all of those interested in buying the lycra-neoprene fabric, please start emailing/pming me your addresses so I can mail you the swatches of lycra and neoprene that I have. You will have to imagine the lycra swatch laminated to the neoprene swatch. I am going to keep on asking companies the cost to dye the fabric, while I gather every one's info. There is one swatch that I think that comes pretty close because it has a mettalic sheen that makes us understand why in some pics it appears like a dark purp, and in some lights it appears lavender. So, I will be asking companies if we could have the same type of lycra but dyed one shade darker of mettalic sheen purple. You will see what I am talking about when you recieve the swatches. We will consider what are the next options once everyone has recieved their swatches.

*EDIT* DCB sent me the color pantone, and printed it out from his color printer to match what the pantone shows. When the lighting is dark, it actually comes out to be a plum color. Pantone #5135 u Lots of lighting probably makes it sorta lavender. Still swatch searching in the mean time.

Sorry, I edited it again 11/9 7:45 pm:
*UPDATE2*:p Neoprene company#1 will not have us pre-dye lycra and ship it to them. Instead they want to double laminate their white lycra version to .5mm neoprene and then send it to another company to sublimate the pantone color onto their white lycra. Total thickness=1.5mm. Their lycra is not shiny enough (too much like a matte nylon color), so, mebbe go with option #2? which is neoprene company #2. I will buy white 4-way stretch shiny lycra have it dyed and then send it to company#2 to have it laminated to one side of the 4-way stretch neoprene foam core 1.5mm, at the same time co#2 will laminate a black nylon on the other side. Total thickness 2.5mm. I am going to see if they will accept a test piece, cause we don't want to waste $ if we don't know if the chemicals used to laminate will work with this type of 85%nylon/15%lycra. If that is successful, then I will mail yall's the actual swatches. It doesn't make sense, but Co#2 is actually cheaper. All the other nylon lycra swatches aren't close enuff color-wize. pantone 5135 is hard to match.
Option#3 (Cheapest way)Go and get dyed this sample called jumbo white spandex (spandex is another name for lycra), It is somewhat heavy maybe .75 mm? It's thin enough and still bulks up a bit like the MOM costume pix, and we might not have to fool with the neoprene, and it's easier to sew. No sweating to death either.

Oops, I am ahead of myself--DCB, did the lycra look matte finish or shiny?

I would recommend that you avoid the dye sublimation if at all possible. Dyde the material first and then adhere to the neoprene if that is the way to go...

splain! splain! so why is dye heat sublimation a not-so-good process? I need to learn... I know nothing about textiles...

Reason it is not good is because the dye willget into the rubber part and then will milk throught to stain your skinor other things.

Well, now we know more about these two neoprene companies. I think I have to search out other neoprene companies. If I can't find one with my specifications, then, we might have to go with option #3. Opt#1=dye sublimation only to get the right color. Opt#2 They will only give us a cut of 1.5mm neoprene with .5mm lycra, and .5mm nylon backing=2.5 mm which is way too thick to sew at the edges(to fold under) You can just tell by dcb's comparision shots on the "bodysuit revelation" thread. You can see that it's thick but not 2.5+2.5mm thick folded under. Option #3 Could be it. Or, I will have to contact other neoprene companies. Those who previously pm'ed me thier addresses will be recieving swatches in the mail, I will mail them out on Tues.

i got ZIA's swatches today...

SH-2 is SO close to the real thing. If that was just a shade or 2 more plum purple - i think we'd have a match. The pix i have from MOM are really hard to tell the color on because of the way the light bounces off the fabric. But it's DEFINITELY that metallic-like finish to it. All the other fabrics are WAY off.

Perhaps you can get a few samples of shades close to SH-2 with the same metallic sheen... we are SO close

Ragrasen is correct on dye sub. Part of the problem is the bleed through. An additional problem is that it is applied with heat. The way that fabric is sublimated to neoprene is by heating up the adhesive so that it bonds 100% to both surfaces (neoprene and fabric). When you go back and reheat it to do other forms of sublimation, you create defects in the bond which will later appear as bubbles or tears. I got this from Glomex when I was screwing with this the first time. That is why I tried screen printing which uses a very low temp. Unfortunately, this is only a 2D topcoat that chips away after wear. If you have inded found a close match on fabric, then you are almost there.

Dan

dcb, what do you think of option#3 and it's sheen? Drop some purple and red dye on it or sumthin. I was told that the metallic-like sheen is actually due to the weaving of the fibers. I know option#3 isn't not lycra and neoprene, but it's thick enough material.
btw, option#1 was glomex. So option #1 is out.

wookie- Man, I didn't realize you got that far with glomax. I thought the rep. paula wasn't much help. well, actually, now I can see why, but... I thought she wasn't much help from the get go. But, did she actually gave you neoprene swatches and explain the dye sublimation?

Oh my this is starting to become a very difficult project is it not. And all those Jango's and Boba's thought they had hard Projects. I think Zam is turning out to be just as hard if not even more complex.

Wrangling neoprene companies is tough. They are sooooo specific on what they need to adhere the fabric. So many guidelines and rules! I've learned a lot, but man- I didn't think starting this suit, I would be doing this. I first thought it would be easy as pie, like putting together my greedo suit. I saw KimnCris's zam from afar at cII and thought, Oh, maybe their already in production.. Boy, was I wrong! Then, I think if I am not mistaken, Don Post was bought out by another company. That was probably a bad merger. That puts a zam out fit WAY WAY out of production, my guess. I mean with Jango, you can at least replicate some of Boba's parts and just tweak it a little. Zam is a whole other story.

*fights bout of major depression....*

Yes... this is turning into a major production. But the costume is just so cool! *sighs*

Ok-- Trying to think calmly here. I am really, really close. The only thing that is stopping me right now is that some of the major neoprene companies won't deal with retail sales other than company#2. And their neoprene stock is too thick. So, if/when (I am working on this one) I get a federal id# I can use, then it will open me up to these other neoprene companies. I mean, we have the pantone color, we have the lycra company, and the dyeing company. We have the thickness we want the neoprene to be...It's just a matter of getting the right supplier who can join that type of lycra to the thin neoprene. By the way, two of you will be getting the swatches a little later than I had planned...sorry, ran out of stamps. But you will get 'em so you can see what I am talking about when I say option/co.#1,2,3 etc.

It is settled now. With all the work that is going into this Zam I can not just leave it on a manniquin. So come one come all to Dragon Con 2003. Thjere is a good chace I will do an hour or so in the Zam there if it is finished by then.

i hear ya ragresen. The girls complain that all the good SW costumes are for boys... but they have the advantage of being able to get away w/ wearing the boy costumes w/o anyone thinking twice... and they get all the cool girl costumes too (zam, boushh, aurra, padmé, etc.)

but a boy wearing a SW girl costume would not be good

We could make up a "boy version" of a clawdite... but that may be bordering on the line of über-geek.

Well if I do the guy in Zam my face will get covered by, yes you guessed it a Clawdite Mask. I am still haveing doubt about doing it because well I just am not into the guy doing female characters. I am doing the costume because I liek the character and will definatly have it on a manniquine (spelling?) for display. And I am regretting to have to actually alter Paul's pieces to make them right. But I am going for the over detailed version.

you know, instead of square pieces you guys could have like leather coat tails! a zam tux!

Thing is I think Zam's Custume or Armor was unique to her. We really have no clue what the rest of the Clawdite race dresses in if at all. They are a race that developed shapeshifting as a form od defense against other Races. So for all we know they never wear a thing.

well maybe with that clawdite book coming out.. we'll see some males.

Wookie, Paula from Glomax remembered you! hehe. I had to tell my rep that it- dyesublimation isn't gonna work. She and I were upset together But the hunt will go on! Company #2 is taking her time getting back to me, cause I'm small potatoes. She is telling me that at it's smallest total thickness could be 2mm. Which equals 4mm when it's turned over to be sewn. That's still really thick at the edges. We'd look funny with huge bulging seams. Until I find another neoprene company, I really think that option #3 jumbo spandex is the best, and most inexpensive. We would have the color we want and a thickness that would be nice to sew. It's probably the clost to the right sheen too.
**NEW OPTION** (I am still calling other neoprene companies) But! Suggested by another member here,instead of double lamination, we could go single lamination. That would thin out the plum material by .5mm So that it doesn't get too bulky when sewing. And, since we have to wear a leotard anyway, so that there is black underneath the top halter piece, we could also wear regular thin black stretch pants underneath the neoprene pants so that we wouldn't have to smell like rubber.

Got my samples yeterday! Thanks so much Zam I Am for all your work on this!

First Option #1 - I agree is "perfect" except that it won't work! The thickness and feel of it seem perfect to me - with a better fabric laminated to it of course.

Option #2 (RL-1) would probably be okay as well, again with the right fabric laminated to it.

Option #3 - I dunno... I would say if we can't get anything else to work out, then we use that - but I'd prefer to keep trying with the neoprene if we can.

A question regarding the color - Pantone 5135 - is that matched from pictures or from your visit to MOM? The reason I ask is that it seems more purple than the color I was thinking of, based on photos. My choice was more subdued... closer to Pantone 5215. Color choice SH-2 was pretty darn close to the color, maybe a bit less intense.

Talked to my seamstress Sunday. After looking at the photos and comparing fibers and thickness, she seems to think option #3 is actually better. She says that 1.5mm is good but still a little on the thick side. If you bend the 1.5mm under and compare it to dcb's armpit area "jumpsuit revelation" thread, you will see how the neoprene almost seems too thick at 1.5mm. The Option#3 actually seems "thick enough" but not too thick. Option #3 is also the most affordable. And, we don't have to worry about laminants ruining the dye of the suit. Dcb picked the pantone when he was at MOM with his pantone book and my walmart paint swatches. Remember, even though you can plug in pantone colors into photoshop, your monitor displays are different. If you have a pantone book then-awesome. Sheen and fabric weaving also plays a factor. He gave me a printout match of the color 5135 and compared it with his actual pantone book color to avoid monitor calibration problems. Hopefully everyone gets thier swatches soon and lets me know what they think. Drop some purple dye onto Option#3 and tell me what you think about sheen. Also, fabrics work differently than regular flat colored paper paint swatches. Color lighting at MOM, etc. is also a factor. But 5135 is the closest we've got. SORRY, I WILL NOT FLY TO MOM and BREAK THE PLEXIGLASS... BTW- it definately is nylon-lycra fabric that is on the actual MOM suit, and what we should/will be using.

I still have not recieved my swatches, but The more I look at things and the more I check things for myself I am convienced that Zam I am is on the right path. Option #3 seems the way to go.

Received my swatches today. Thanks zam i am!

After comparing to pics and re-reading this thread again, I think I'm going to agree with MaulMaus.

MaulMaus wrote:
First Option #1 - I agree is "perfect" except that it won't work! The thickness and feel of it seem perfect to me - with a better fabric laminated to it of course.

Option #2 (RL-1) would probably be okay as well, again with the right fabric laminated to it.

Option #3 - I dunno... I would say if we can't get anything else to work out, then we use that - but I'd prefer to keep trying with the neoprene if we can.

Cal

http://www.printroom.com/ViewAlbum.a...lbum_id=112954
Sorry they aren't hi rez picks. But, here are the picks of the swatches. Sh-2 is second swatch in from the left on the first picture. Please comment, should I keep on looking for Neoprene companies? Remember, neoprene companies cannot get thinner than 1.5mm. Or, should I stick with Option #3. Thick lycra.

I haven't recieved my swatches, but if I'm understanding this thread correctly, I'm leaning more towards Option #3.

I am on a Lord of the rings kick-- So now we have the fellowship of the body-suits..heheh So far the decision has been equally divided between Option 3, and me looking for more neoprene companies. Remember, I haven't gotten a federal id number yet, so it could take several months for me to get another neoprene company to agree to this. AND, I will not be able to talk to overseas companies. The prices would be astronomical, and they wouldn't want to invest/spend the $$ for me to just to do a test lamination. Option 2 is doable, but a bit too thick on the neoprene side. 2mm folded over is really bunchy. Plus us wearing a leotard under that stuff would heat exhaust us. So, if the fellowship stays together, we could wait to if I come up with any other neoprene companies. Or, we could all decide to just go with the jumbo spandex. But if the fellowship breaks then everyone will be on their own. Cause, it's just not cost effective. Paying over $200.00 per person, just for fabric is ridiculous.

Okay, got my swatches. There was no Option 1 or 2 pointed out on my sheet of paper.. only an Option 3 which pointed out SH-14. Am I to understand that the Option 3 fabric would be dyed the right color and would need no lamination?

I like the look and feel of GL-1 personally.

Sure, it's not the right color but I think it looks fine.

Can you tell it was a late night for me? !@#$%# ok, Let me re-itterate. GL-1 is option#1 This one is not available to us because it requires heat sublimation dyeing process= way expensive and very bad outcome. This swatch is only a thickness reference. It is a very nice,almost perfect thickness. http://www.printroom.com/ViewAlbumPh...954&image_id=1

RL-1, is option#2 It is 2mm-3mm thick and possible, but too thick when turned over and sewn. They can possibly laminate our pre-dyed lycra to their neoprene. We don't know if there will be glue problems. Or, if the lamination process will ruin the dye. This process would have to be tested. (Which isn't free.)We would also be wearing a leotard underneath. This option could heat-exhaust us. This particular company can't cut the neoprene smaller. 4-way stretch. We would have a white version of sh-2 dyed and laminate it to the neoprene. Test dyeing is also an added cost. http://www.printroom.com/ViewAlbumPh...954&image_id=2

sh-14 is Option#3 Thick nylon spandex. It is less than 1.5mm but more than .5mm thick(Spandex and lycra are the same material, just different names) No neoprene on the backside, but "thick enough" for the bulging welted seams. We can have it dyed and it is a two-way stretch. No glue problems or extra funds expended for neoprene testing. Just extra funds needed for the dye test. Cheapest option. No heat exhaustion problems either. http://www.printroom.com/ViewAlbumPh...954&image_id=5

Voting at this point, 1)is for me to somehow get a federal ID number and eventually find the "right neoprene company" that will give us total thickness 1.5mm double laminated neoprene with one side being our dyed sh-2 like lycra. Keep in mind this could take several months. Or 2)go with option #3 have a pretest dye job and then get enuff for all of us.

Thank you SOOOO much for reiterating. You're awesome. Everyone was throwing in suggestions and saying I like Option this and that and I was totally lost.

It all makes sense now. It's too bad about Option one not being feasible. But that all said and done....

I go with my original opinion and think Option 3 would be the best way to get it done. I also like the color of SH-2 but I will go ahead and check the pantone # to it.

TheWookie wrote:
I'd like to see what option # 3 looks like dyed. I'm afraid of dyeing it as I went down this road before. Who are you having do the dye work?

A company in new york. Dynamic dying company or something like that. They usually do 3000 yards at a time, so I would have to pay for a pretest if we dyed it. See, here's the thing, either I do sh-2 in white and dye it for some future neoprene company or I do sh-14 and dye it. I don't want to have to shell out so much dough for so many pretests. That's why I want people to choose. Either I keep on lookin for other neoprene companies (which will take me months)or go with option 3.
We would get a pretest, my seamstress would sew in a welt seam prototype,and then send it out to everyone to say a final yeh or nay. But if the fellowship of the body suit breaks apart, I will not be able to order any of this at a reasonable price, even for option #3. I will not do any purchasing if people have to pay over $200.00 per person just for the fabric.

What would we need to do to get a pretest done for option #3 including having the seamstress make a seam?

For whatever it costs for a sample I'm sure we could all chip in a few bucks to get it done. This might help the final decision. I must say I'm a bit skeptical as to how this option will turn out but I'm willing to help get it done so we can have something more to go off of.

Unfortunately, I won't be able to check in until Sunday night as I'm leaving town for the weekend.

Cal

The cost would be about $10.74 per person if we did a pretest for Option#3, and if EVERYONE chipped in. People, if you are interested in the pretest, please pm me that you're interested. My paypal is ZamIAm@comcast.net If you want to mail me a check, pm me for my address. Please don't paypal me just yet. I have to get everyone to say that they definately want to do a pretest for this option. The price will fluctuate if the total "fellowship" doesn't participate.

I must say you all have really stayed the course, you all really make me proud to be a part of tdh I'm gettin teary eyed... When I've lost my patience, you all haven't... Thanks ya'll. *sniffle*

Awww.... MonCal beat me to it!

Count me in for the test - don't think there is any other way to really know how this will turn out. I'd rather pay a few bucks now than regret any decision (one way or the other!). JMHO.

I have conversed it over with some people in the group. And seeing as how most people are really into the neoprene 1.5mm, I am going to research more neoprene companies until this happens for us.
Q:What about Option#3?
A:Since we all want to save money, and shipping costs so darn much, we are going to wait till I acquire a Fed Id# and get a pretest of a white lycra sh-2 dyed with a correct pantone laminated neoprene sample. Then we can do the two pretests at the same time. The dying company might give me a color test break. Both samples will be sent together. Then we will decide.
Q: How long till you get a Federal Id#?
A: Don't know. It may take a couple of months before we all recieve swatches of the real thing in our hands. Still in the asking.

Just wanted to let you know, if you guys dont hear from me for awhile regarding the body suit, it's because of the holiday season, and I have to give a piano recital/concert. So, sorry to have to perpetuate the patience. But! If you have found a Neoprene company within the US that isn't Glomax or Rubberlite, Let me know. I will make every effort to contact them and try to get these companies to cooperate regarding what we want. Thanks for your patience.

I like that idea. I'm willing to wait it out until we can come up with the best possible solution.

(as long as it's within the next decade)

I'm a little worried option 3 will be too thin. I know the costume will probably be hot but it's not like it's going to be worn every day and besides my wife will be the one wearing it, not me Most of these costumes are warm anyway.

Thanks zam i am for the effort!

cal

Actually, I am hoping to get the federal Id number next week. Everyone thinks that 1.5 is the correct thickness. If I can forego Option#3 then I will. I will admit it's a good option, but not the best. Let's hope the other manufacturers won't give me flack. I think we will just do pre-testing for the neoprene, when I get hold of a company with our standards met. You see, pretests for the neoprene is more expensive. you need four yards of lycra fabric just to roll through the machine. There is the dying, then there is the neoprene too. I will try asking for open cell foam, it's a lot more breathable.

Do you still need donations to help contribute to the cause? I was on this board months ago seriously looking to start this outfit, but my wife and I moved out and $$ has been tough for a while, but I'm slowly looking back into this.

What donations are you asking for and will any of this be applied to when we purchase a final outfit from it? Curious.

Thanks for offering donations, but right now, it's pretty settled that we are gonna wait things out for a neoprene company that will give us exactly what we want. 1.5mm double laminated with white sh-2 nylon/lycra dyed to plum pantone 5135. Open cell foam, if possible. Once I get a neoprene company that will give us what we want, then I will be posting about a future dyeing and neoprene lamination pretest. Unfortunately, pretesting the fabric will be a separate charge from the actual 5.5-6 yards of material people will purchase. But for now, I am just waiting for the fed id to come through.

Sounds like a plan.

Thanks for doing this Zam I Am!

Best of luck on your piano recital.

Gee, shucks, tanks.. for wishing me well on the recital. I should have learned the sw theme, so that I couldve played that too, darn. I could've turned all my students into jedi-younglings! hehe. The musical force is powerful

My sister plays trumpet. She played in the High School marching and concert band and now plays for her college marching band.

Mr Fett plays drums.

I wish I had learned a musical instrument... guess it's never too late.

Many appologies to the powers that be for getting off topic.

I had a friend back in TX that could play the Imperial March so good it made me think i was living the movie (even though if you think about it there isn't any sound in space) sorry thats way OT

getting more ot- my hubbie hooks up an mp3 player speaker to the front of his vader mask and plays the vader theme, and it's hilarious when he walks by our 501 troopers and people are wondering where the music is comming from. Then you hear his breathing. It's like having John Williams with you and you're in the movie

Hey all,

I have been watching your progress on the Zam suit. I am pretty impressed with the seriousness this project is evoking.

I have to agree that the MoM pics look like the fabric is backed with open cell foam.

If it is not too late, I would like to join the "fellowship". My fiancee has been requesting a Zam costume for several months.

Thanks,
Jack
Dark Trooper

Welcome aboard. I am sure haveing another person helping out will make this work faster. Lately I know I am begun to feel we are getting close to exhausting our resources.

Yeah... I donated some $$ toward the cause and I'm looking foward to getting a well made ZAM suit for my wife too. It'll be so worth the money.

You mean, you donated $$ to Dallas for his pics right? Cause, um... I wasn't taking donations. Should I be checking my paypal?

Yes, it was Dallas. Thanks!

Welcome to the fellowship, dark trooper. By the way guys and gals, it's taking me a bit longer to get this fed id number. I don't think pretests for this suit will be available until after the holidays. I am sorry. Anyone just so happen to have one they can throw my way?

Wish I did....

I'm not worried about rushing through this - if it's after the holidays... then it's after the holidays. I'd rather get it right. So relax and enjoy your holidays Zam i am...

I agree with MaulMaus.... it's not like I'm going to be able to afford it until after the holidays anyway...

So relax, and once the holidays breeze by, we'll get back into the swing of things.

I'll officially agree with the previous two.
Don't sweat it. Have a great holiday season and as soon as the new year arrives I want my suit

No really, whatever it takes I'm in no hurry and am willing to wait until we can get it done right.

Cal

Thanks yall. I only have time to possibly finish my greebs this year. I have two jobs and it's always really difficult during the holiday season time wise, cause both jobs are getting really demanding. THe fed Id thing is slow going too. We'll see.
Mon Cal-Yes sir! j/k Really though, thanks for yall's patience. Hopefully this will pan out and santa doesn't run me over with his sleigh so that this project WILL happen.

Good news! Yall! I have a federal ID# to work with. Thank you to the person who has helped me out! you know who you are I have to keep in confidence certain things, so as to not get anyone in trouble. But YEH!!!! I will have to talk to some people and then try calling some of these other companies. Hopefully they are all american companies. But, we'll see.

Excellent work Zam I Am!

Hey, I haven't really worked that much on it this week, but thanks for the compliment! You'll hear more next week about the suit- this week is the recital. Saturday I have to play the Chopin's Revolutionary etude to show my students that I can actually have some talent . That would be funny to be able to play with greedo hands

Update on the neoprene search- I am running outta neoprene companies to call. I have called three others and it hasn't been good news. I now have two fed id numbers I could use (thank you-you two who have helped out). But I am having trouble with thickness. Apparently, most neoprene companies over here stateside are only creating neoprene at 1/16" Then laminated to lycra, that goes over our 1.5 mm thickness mark, Which is way thick. It's closer to 2.0 - 3.0 mm when done. So search is still going.

Thanks for the update!
Good luck with the search


Cal

Update, Happy New Year folks, sorry this has dragged out for such a long time. I have been really busy with family and personal stuff, so sorry, but I prolly won't be able to get much done right now as far as calling. The company I work for is really demanding, since it's end of year, and I can't make as many phone calls during reg business hours at the moment. What do you think if I had my seamstress do a welt seem with my 2.0mm fabric, I take pics, and if everyone thinks it's feasable, we would join the rest of our friends who die from sweating? And get a color/lamination pretest done with that? I will search neoprene companies later in Jan, but lemme know what you guys think about this idea.

"seems" like a good idea to me

That should help us to decide if it will look the same.

I think we all understand about being busy this time of year so no worries

Do ya need a couple bucks from some of us to pay her to do it?

Sounds good to me too! Do you need any funds for this test run?

And I concur... don't worry about being busy! No apology necessary at all! I'm just grateful for all the work you've already done!

Works for me.

Also maybe it is time to start a new thread for this?

Well, I am gonna ask her then. I think she will do it for me at no cost. I will ask her to do it and see if she just says, ok. But the pre-testing will be a chore and pricey. I know for a fact that those underarm seams aren't gonna look right, but everything else might. Oh, the top of the pants might also be a problem, I am not sure. I think if the fabric is scored, then maybe it will look ok and won't bow like a big loop at the top, same with the pitty area. We'll see.

I just asked my seamstress and she will be doing this on Friday. Using the swatch of 1/16th neoprene/lycra that I have, she will do a welt seam and a seam like as if the top part of the pants. She said that she will grade the seam so it won't look so bunchy at the top. We will be able to have this done so that we can see how it all looks and imagine how it would be for the arm pit area. I will do comparison shots and ask Dallas to post them later (prolly Saturday). If this all looks good, then we can use the 2mm for the pretest.

Zam I Am, you're the best.

Okie, here goes guys, if we do go with that 2mm Neoprene, then it has to have nylon on the back or else my seemstress or anyone else working on this stuff, will have a hell of a time sewing it. The rubbery neoprene stops the fabric from moving under the sewing machine's needle. Therefore, nylon backing is a must. The top piece is called a long sleeved crop top. Definately welt seams there. On neoprene a flat feld welt seem would be entirely too bulky. So, with all that in mind, I will search a couple more neo companies. Goto this site for a welt seam in neoprene. (keep in mind, she didn't have nylon backing, just the rubber neoprene that's why it's not a straight line)
http://www.printroom.com/ViewAlbumPh...54&image_id=11

Honestly from what I can see in that picture is fine. The welt seam looks pretty close to what we see inthe Zam pictures. Maybe I am missing something as the picture lacks shadows and may make it lookflatter than it really is. Zam think you can get a side shot up and posted?

Ok here's the link, got a shot of it on the side of my arm and my husband's.
http://www.printroom.com/ViewAlbum.a...lbum_id=112954
Ya'll tired of waiting and wanna do the pretesting? I will call the 2.0 mm neo company tomorrow and ask for pretesting price. And, you wanna forgo option #3 pretest? Or do you wanna go with that one too? I thought, well, it's thicker needles and we gotta sweat a little more, but it gives the right thick look. LMK

From what I can see the seams look proper to me. I think we should go for it allready.

From what I can tell the seem looks right. Since you can see it in person, how do you feel about it?
As for the neo company, let's give it a try. We pretty much know what we are looking for.

Lets Pretest! The seam looks nice.

MonCal wrote:
From what I can tell the seem looks right. Since you can see it in person, how do you feel about it?
As for the neo company, let's give it a try. We pretty much know what we are looking for.

At first, I thought that the example was .5mm too thick for the edges of the long sleeved crop top and the top edge of the pants when sewing, but it's not that bad of a difference. All the other neoprene companies are overseas companies. I really don't want to deal with overseas, because it requires a LOT more aggravation with shipping, money exchange, etc. just to get 1.5mm total thickness. I think that once the nylon backing is on, the seam would be perfectly straight. And, like I said before, everyone would have to research thicker needles and sweat a little more, but overall, this looks pretty darn close once we have the right dyed lycra. I think that this is our best bet, since option #3 is not quite the right grain of material. sh-2 is most accurate, then dyed and laminated to the neoprene. This will work out because the neo company can leave the lycra on the sheet instead of trimming it off, so that the top part of the pants, and bottom part of the crop top won't have to be folded over equalling 4mm. The lycra would just curve over the neoprene. Here's an illustration:

Thanks for the illustration and all your hard work.


And.... where did our team banners go!?!?

I just talked to the rep. she wants to know if we want the neoprene that is open cell or closed cell. If we get neoprene that is closed cell, then you could probably swim in it, but it isn't breathable. If we get the open cell, it's breathable. There may or may not be a price difference.

This is looking good!

Well... I didn't plan on snorkeling or anything in costume! *LOL!* Though, we may be sweating enough in these things to actually go swimming! IMHO breathable sounds more comfortable - if it really is "breathable."