Hey guys! So excited to join this group of passionate and imaginative people, the stuff some of you guys are doing is super inspiring. I decided after some searching around to give making my own neck seal a try, I think it came out okay, considering the whole thing costs about $10 to make. Please let me know what you think, I'd love any feedback.
First I went to Home Depot and picked up a package of this stuff:
http://www.homedepot.com/p/Frost-King-E-O-5-16-in-x-1-4-in-x-17-ft-Black-EPDM-Cellular-Rubber-Weatherstrip-Tape-V25BK/202844545
It's great because it's got two round 'tubes' per strip, with adhesive on the back. I then went on a half day long search for a black turtleneck, to no avail. Who knew finding turtlenecks was actually really difficult? Hmmh. So then I had the idea that maybe the arm of a T-shirt would fit over my head! Turns out a 2XL worked pretty damn well. So I cut the sleeve off from the shirt, leaving some material that I could tuck inside my compression shirt later.
Once I had the weatherstrip and the shirt material, I simply removed the adhesive backing and started applying the strips in rows to the sleeve. Surprisingly the weatherstrip stuck really well to the shirt and I didn't have to use additional adhesive. I butted the rows up against each other and cut them with a razor blade. I decided to do four strips, giving me eight tubes. For me this fit nicely up against my chin, and gave me enough room around my neck that it didn't choke or rub against my adams apple. You could adjust this to your preference, obviously.
Once I had all the strips installed and trimmed, I cut a slit down the sleeve where the tubes met. This is necessary so you can actually get your head through. Go down only as far as you need to get your head through. Then I e6000'd velcro pieces over the ends of the tubes, which both cleaned up the edges and mated the strips to the fabric, keeping them from separating over time. I wasn't sure how this would look but if you look at some photos of Han in ANH, you can clearly see a velcro or similar closure on his seal. For now it's okay, I may revisit/clean this up eventually.
My only little gripe is that maybe the tubes themselves are a little too thick, I'm currently looking for a thinner version of this weatherstrip. What do you guys think? All in all this seal took about an hour to make, and again cost about $10 so even despite some minor issues I think it's a worthwhile build.