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Discussion Starter #1
So my wife, the professional fleece seamstress, has finally agreed to make me a one-piece suit! Because this has taken years of begging I want to get the fabric and design perfect. I want warmth for skiing and use under my drysuit. I also want it to double as footed pajamas and a bear costume.

What fabric should I use? What features would I be a fool to leave out? Any improvements on existing suits y'all can think of? Has anyone out there made their own union suit?

This may be the most important decision of my life so thanks in advance for the tips!
 

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Custom union suit - that is badass, you will need to post pics. I love my bunny suit from Stohlquist but would make some changes. Go with something wool based (assume you are but), eliminate any zippers, and have both relief slots. The feet idea would be nice too. Hard part will be figuring out how/where to enter. LL had the super stretchy neck but that never worked well for me. My biggest dilemma would be how thick of fabric/warmth factor...
 

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Discussion Starter #4
Not going with wool. Poly fleece will be more affordable, more durable, and is more sustainable. I like merino tee shirts, but I want a thicker, warmer option.

A zipperless design might be a great idea though...
 

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I just bought an IR union suit. It is zipperless, so you step into through an elastic neck collar. Super nice! no zippers or anything else to cause discomfort after you get suited up.
 

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I just picked up a few ninja suits from air blaster on prodeal.... they are unreal... got a poly version without a hood . and a merino version with a hood.... will never look back! zipper becomes unnoticeable once in drysuit. etc. I use one for drysuit , one for skiing.... they were 55% off with prodeal.... also got one for gf and she is in love... they are perfect! so comfy!
 

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more like a base layer.... a prodeal on the poly suit would be like 50 bucks... they are performance gear... the fit and the material are what you would expect from top of the line base layers like icebreaker... the hood is actually a helmet liner... its sooo stealth and bomber.... im short and heavy and xl fits perfect... and the material is very stretchy...
 

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I have a couple of the old thick fleece bunny suits from Stolhquist.

super warm, have worn like iron and still good.

I purchased a couple as back in the day we would boat on weekends. The damp fleece would be either super cold or some times frozen so I kept one in the truck cab and would warm it up a bit sunday morning before getting on the creek.

If you do buy or make the bunny suit, be sure the front zipper unzips from top and bottom so you can take a whiz from the open dry suit pee zipper.

these suits make excellent warm ups under rain suit pants and help out a bunch on cold nights in your sleeping bag
 

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Discussion Starter #12
Just out of curiosity, what's unsustainable about wool? What's sustainable about polywhatever?
Merino wool comes from sheep that drink water, eat food, and live on the other side of the planet. I'll buy recycled poly fleece from Polartec, which is made in America from waste materials and shipped a fraction of the distance.

Don't get me wrong, I love me some Merino, but it's far from a sustainable material, IMO.
 

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Discussion Starter #13
If you do buy or make the bunny suit, be sure the front zipper unzips from top and bottom so you can take a whiz from the open dry suit pee zipper.
This is a good tip - thank you!

We found a pattern for an adult bear costume that's going to work perfect. I'll post a picture when it's done. It's going to be my drysuit liner on freezing days, my winter lounge wear, and a good Halloween costume!
 

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Something else to consider is draft flaps over any zippers to keep the cold out and avoid contact with cold zippers. This would be a nice touch.
 

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Merino wool comes from sheep that drink water, eat food, and live on the other side of the planet. I'll buy recycled poly fleece from Polartec, which is made in America from waste materials and shipped a fraction of the distance.

Don't get me wrong, I love me some Merino, but it's far from a sustainable material, IMO.
That is interesting logic... more power to you if you feel petroleum products (albeit recycled ones) are more sustainable than natural fibers - The shipping argument is legit but I think you're seriously stretching the sustainability argument. Now if you just feel bad for those poor sheep that go to all the trouble to grow themselves a nice coat only to have some asshole human come and sheer it off that would be understandable :roll:.
 

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Discussion Starter #18
That is interesting logic... more power to you if you feel petroleum products (albeit recycled ones) are more sustainable than natural fibers - The shipping argument is legit but I think you're seriously stretching the sustainability argument. Now if you just feel bad for those poor sheep that go to all the trouble to grow themselves a nice coat only to have some asshole human come and sheer it off that would be understandable :roll:.
There are 39 million sheep in New Zealand. The impact of this agriculture, which exists in large because of wool, is probably staggering. It certainly has enormous ecological and resource impact. And then we ship it across the world so people can buy it as a luxury item and call it sustainable or renewable. It's not a green product, but it hypes itself as one.

Polyester fleece, made in America, and 50% of which is made of recycled plastic, does come from petroleum. Just because "oil is the devil" doesn't mean the impact of its products is greater than all of their alternatives. Very little petroleum - plus a bunch of plastic bottles that could have ended up floating in the Pacific- make up what it takes a living, eating, shitting sheep quite a while to produce.

I dig Polartec and the "keep it here" business spirit so I'm probably a bit biased, but I think their product is more sustainable than wool. I'd love to hear from someone who knows more...
 

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Discussion Starter #19
Something else to consider is draft flaps over any zippers to keep the cold out and avoid contact with cold zippers. This would be a nice touch.
Andy, thank you. Definitely going to include this behind a big 2-way zipper. This bad boy is going to have to last a lifetime. It's rare that I can get her to make something after she sews all day for a living.
 
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