Double snaps everywhere, even on limbs. I will have to order more snaps! I do just to be safe but others are fine with only one snap, my main area I've had snaps fail was shoulders and having the spare meant I could keep trooping
Nylon is used on the armor side, elastic for connections Correct, in some areas double over the elastic for strength, shoulder strap chest-backplate, also abdomen-kidney
Nylon looks like it's 1" wide and 2" long. I've seen people use ABS instead, or sandwiched ABS inside nylon. Seems like if the armor is thick enough, and I'm using authentic E-6000 glue, I should be good to go with just nylon. I just find nylon conforms to the armor better and you don't need to recess the snap but you do with plastic snap plates, but either way works fine. I do have small pieces of ABS strips I use on both sides of the nylon to clamp down so it stays flat when drying.
Elastic is 2" wide, and its length will depend on what sections are being mated. Using discretion, place female snaps 5mm shorter than where they should be when the elastic is relaxed Elastic sizing info here From the Supply List:
-. Elastic- 1 inch wide black for shoulder bells, etc. (4 ft.) 2 inch wide white for ab/back plate shoulder connection (1 ft.), 1 inch wide white for drop boxes, (1 ft.) 1/4 inch wide white** (1 ft.) for shoulder straps.
-. Nylon strapping- 1 inch wide black, at least 6 to 8 ft. long. 2 inch wide black (48 inches) for high tension areas if you are using the double snap method. (NP)
Double over ends of elastic so snaps go through more material = strength. Some areas you can but depends on your snaps, some have shorter posts and you can't double over the material
Make a jig with two holes in it to ensure that snap spacing is the same everywhere. Burn holes with soldering iron using this jig. Also, using the iron, seal the edges of the nylon and elastic so fraying is prevented. Just makes life a little easier using a jig, in case you make any too short or long you can use in other places.
Sound OK?
Is there any strapping that goes between the thighs and shins to maintain that gap? Otherwise it seems like the shins could droop quite a bit. Not between the thighs and shins, the shins sit on top of the boot, thighs are held up with belt/harness. Some add a loop of elastic or velcro in the top front loop of the boot which connects to the inside of the shin to stop them coming upwards or rotating. I have mine on the front, some add them to the back
I think that's everything