2nd Bat
Master sergeant
Posts: 11,813
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Post by 2nd Bat on Sept 27, 2016 17:33:02 GMT -5
US GI leggings add so much to a GI impression and it is one of the most iconic looks of WW2. Vintage and reproduction khaki canvas leggings are fairly abundant and fairly affordable typically running around 20 bucks or so. Their build quality was such that even sets 75 years and older are fully serviceable with little worry about them holding or wearing out from use.
So why tackle homemade builds? Whether vintage or reproductions they are absolutely miserable to put on! Obviously this is one of the reasons they were so unpopular with GIs and Marines. When everyone has their own pair and has worn them several times this isn't typically a big deal (in fact it becomes part of the living history experience). In my case I usually find myself gearing 10-12 walk-ons who know little about WW2 uniforms and precious time is squandered getting folks outfitted and ready to participate. For my GIs leggings are the biggest hiccup. Even reenactors frequently get them on wrong and I noticed some retailers displaying them incorrectly! The laces and hooks should be on the outside to prevent snagging and the hooks should be facing the rear. Buckles on the outside. Another loaner gear issue is most vintage leggings run in smaller sizes. Even the larger sizes struggle to fit around the footwear some walk on players show up with. Hiding inappropriate footwear is one of the great things leggings and German gaiters accomplish.
So what is my latest project to remedy this hassle? I decided to tackle making my own "Hollywood" leggings. These will look the part (reasonably so I hope) while being quick and easy to put on and take off. They will be big enough for everyone and adjustable to a wide variety of wearers using the hidden Velcro.
Another inspiration for this project is my parts bin had a bunch of take off canvas strapping and buckles and I came across a large batch of appropriate khaki canvas. A large military radio cover that I bought at a flea market and which was doing me no good.
To begin my project I took a pair of reproduction large leggings and disassembled them to use as a pattern. Leggings require more canvas than I thought! Also period correct canvas is hard to cut! My plan is to design a wrap around that will have the hooks and laces permanently affixed and extend the wrap a bit beyond where hidden Velcro will actually hold the leggings in place. The arch strap and buckle will be all that will need to be affixed by the player.
Today I cut out the materials needed for four pair. The Velcro will allow for flexible fit out of each pair. Once finished I may take some on hand reproductions and try separating the rear or front seam and create a line of Velcro there as a means on making them more usable for my purposes.
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2nd Bat
Master sergeant
Posts: 11,813
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Post by 2nd Bat on Sept 30, 2016 17:15:57 GMT -5
My spacial relations talents are horrible! I attached the Velcro strips to three sets of leggings only to discover that they don't marry up! I attached both surfaces as though they would be on the inside surface of the opposite seams. So obvious and yet.... arrrrrrggggggghhhhhhh!
Not the end of the world but extra work none the less!
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Post by volkssturm on Oct 1, 2016 16:30:22 GMT -5
In my younger days I tried making a backpacking tent. I had to rip out several seams when I realized I had sewn things bassackwards. It's a real palm-meet-forehead moment.
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2nd Bat
Master sergeant
Posts: 11,813
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Post by 2nd Bat on Oct 2, 2016 1:30:54 GMT -5
The axiom of measure twice, cut once is also applicable with sewing projects. Leggings are far more complex than I ever would have imagined. Making some progress however as I have two fully assembled and four more in progress. A couple cases where I got inside surfaces confused with outside surfaces and worse too many "left" pairs. To remedy that boo boo I'll end up with another pair ultimately.
In the finishing stages one realizes how many holes and eyelets are needed. Army leggings used more hooks than the leggings used by the USMC. The eyelets and installed hooks are helping to secure the inner flap although otherwise the hooks and laces will be cosmetic only and totally non functional.
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2nd Bat
Master sergeant
Posts: 11,813
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Post by 2nd Bat on Oct 2, 2016 20:34:37 GMT -5
So as I near the final stages of this project what have I learned that I can share with others? Definitely NOT worth the time, trouble and expense. By the time I add up materials costs it literally would cost more to make these than the cost of buying (and shipping) actual decent sized, functional GI gaiters or reproductions. The end result looks decent (obviously not as good) as actual gaiters and will work as intended but require FAR more time, effort and frustration than I had anticipated. Modifying reproduction leggings by adding a flap with Velcro strips is hard enough and provides a better end result.
On that note I found the best approach for modifying gaiters is to slice the leggings along the seam just to the rear of the hooks. I fabric glued the laces and hooks so they are permanently affixed and clamp them into place allowing them to dry overnight. I likewise glued a thin strip hem along the fresh cut canvas to prevent it from unravelling. I then attached a two inch inner flap to the leggings extending the cut section so it tucks under the laced hooked section. You can then sew or in my case fabric glue the facing strips of opposing Velcro. Do so in such a way that you allow this wrap to adjust and tighten according to the wearers sized legs and ankles. This of course would normally be done with the lacing.
I had concerns that the fabric glue on canvas wouldn't be strong enough but thus far they seem to be fine. Will weather and field use separate these seams? Time will tell. My fully homemade leggings look fine but not as great as I had hoped. In hindsight I wish I had patterned my homebuild on actual leggings taken apart instead of reproductions as the real gaiters have a more hourglass shape than the repo I copied which were more cylindrical. Fine for my costume needs and a good learning experience. At some point I may try to tweak the four I made to correct the look.
I think my riggers pouches made from the scraps will be a happier result! I think I need to leave the sewing projects to Drac! The canvas is way too thick to run a sewing machine on and paying a commercial vendor would have been very expensive in a limited volume order.
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2nd Bat
Master sergeant
Posts: 11,813
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Post by 2nd Bat on Oct 3, 2016 15:18:28 GMT -5
Final details on the six pair I ended up fabricating is being done today. Hopefully I will have time to complete them. In addition to the six homemade sets I have also managed to modify three existing sets of leggings into Velcro fastened "Hollywood" leggings. In sorting through all my leggings I have three mismatched individual gaiters (all right sides) and assorted styles, shades and hook patterns. Laces are also missing or broken on several sets. Obviously their partners must be hiding somewhere in my stash of stuff! Frustrating.
In issuing all these out at events things get lost or misplaced. I think the simplicity of the Velcro will help in this regard. Certainly broken or missing laces will no longer be an issue. I have devoted a week on this project, used up a bunch of on hand materials and hopefully will find the effort worthwhile at the next event!
As always if anyone wants pictures of the process just PM me along with your direct email and I will send photos of the process.
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Post by insterburger on Oct 3, 2016 20:19:56 GMT -5
Saw the pics of these. They look awesome.
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2nd Bat
Master sergeant
Posts: 11,813
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Post by 2nd Bat on Oct 3, 2016 22:19:26 GMT -5
They are quite passable in my opinion and with each one I manage to improve and enhance each set. I have put them on and taken them off several times with no issues over a wide assortment of footgear. I think they are going to make my life a whole bunch easier.
From a practical perspective modifying existing leggings is the way to go rather than full scratch builds and I'll try to post a photo tutorial on the process. The fabric glue is fairly expensive but with good clamping it is remarkably strong (at least thus far). A $5.00 tube of fabric glue was enough to attach the inner flap, do the border seams and attach the Velcro for three sets of leggings. A single package of Velcro strips ($2.29 ) is enough for one and a half sets.
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2nd Bat
Master sergeant
Posts: 11,813
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Post by 2nd Bat on Oct 11, 2016 22:52:38 GMT -5
Still doing occasional detail work on these and will be modifying a few more actual sets when my ebay acquisitions arrive. I managed to buy some individual spats that will finish off lose individual leggings I came across and couldn't find matches for. (For some reason I had three un-matched right sides?)
I bid appropriate matching individual sides and won each at the starting bid. These will be Velcro gaiters before my next event which will give me 10 sets of quick on gaiters.
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2nd Bat
Master sergeant
Posts: 11,813
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Post by 2nd Bat on Oct 26, 2016 18:46:15 GMT -5
Finally found the time to finish these up! Ultimately doing up 10 sets of these was a lot of time consuming work but I am very pleased with the end result. I don't have a big event planned until the Spring but these are going to really enhance the overall look while making my uniform issue way, way easier. I did find I needed to extend the Velcro a bit beyond simple strips to allow some level of adjustability to the fit. Without it each pair was essentially a one size fits all and without the ability to synch them tight they looked funny, weren't comfortable and provided no support. The Velcro holds incredibly well. The fixed laces came out quite nice. (They are fabric glued into place.)
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Dracul
Master sergeant
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Post by Dracul on Oct 27, 2016 9:07:18 GMT -5
A few tips. You might want to take the extra bit of time to stitch them in. Eventually the fabric glue will wear off, especially if guys are wearing these through mud and rain. Just a few simple stitches at each corner of the velcro, and when the glue wears off (when, not if) there won't be a complete wardrobe malfunction in the middle of a game.
Also, using velcro with thicker widths (or multiple thin ones lined up side to side) will secure them much better, and less likely to come off in the field. Trust me on this, I made enough costume items that used velcro as the closure/securing method when I didn't have supplies or time for a more proper one to know that thin strips is not enough (think leather gauntlets that come undone from just flexing my forearm).
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2nd Bat
Master sergeant
Posts: 11,813
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Post by 2nd Bat on Oct 27, 2016 18:07:22 GMT -5
I used a commercial grade (actually military surplus) Velcro which I had (for some reason) in both TAN and OD. I am sure that with exposure to the elements there is a high likelihood that the fabric glue alone isn't going to hold and that corner stitching (at the very least) will be required. This is going to be a ton of work if and when I get around to it. I have been walking 3 to 5 miles a day as an exercise program and will stress test a pair of these when next it rains and deviate from the trail through wet brush to see IF and how well these hold up.
I fear you are correct but ever the optimist I am hoping to be pleasantly surprised.
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Dracul
Master sergeant
Posts: 1,341
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Post by Dracul on Oct 28, 2016 6:21:19 GMT -5
Regardless of grade, standard properties of velcro don't really change. There is just simply not enough connection with 1 inch or thinner strips. Modern use of velcro by military is always at least 2in thick, or more (sans name tapes, but even then, a lot of use just stitched them on, just to be sure).
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