X-Wing Pilot Uniform — Flak Vest

Source: Rebel Legion


Source: Rebel Legion


Source: Rebel Legion


Source: Rebel Legion


Source: Rebel Legion

Making Your Own

Making your own flak vest is much cheaper than buying it. It really isn't that hard (time consuming though), even if you have very few sewing skills like me.

Parts needed:

• Fabric - I used white polyester fabric with a little texture.
• 2" White Elastic ($1.69 for 1 yard)
• 1" White Webbing ($1 for a yard)
• Clear Aquarium Tubing
• White Industrial Velcro (a pack was $3 from a fabric or hardware store)
• Large Sheet of Paper for Pattern (I used brown boxing paper)
• Shirt Pattern - to cut arm holes on your pattern.
• Black Metal Military Tie Down
• Insertion Locks
• Two strips of leather

Source: Dewback Wing/Division Five (Please note that the above dimensions will not fit all body builds. See my dimensions below for a larger size.)

I couldn't find a good pattern for making a vest so I made my own. Put on your flight suit and measure 1 1/2" from the base of your neck down your front and make a mark. Then measure 3 1/2" up from your belly button and make a mark. If you measure the distance between the two marks, you should have how tall you vest should be.

Unsewn Dimensions
These dimensions accomidate 1/4" seams and is measured to my 6' 2" build. If you are 5' tall I suggest you measure yourself.

Front Base: 19" wide x 13" tall
Back Base: 19" wide x 14" tall
Front Ribbing: 24" wide x 18 1/4" tall
Back Ribbing: 26 1/2" wide x 18" tall

Fabric: There are various debates about what fabric was used on the flak vest. I have chosen to use a basic lightly textured snow white polyester. Polyester is easy to find and inexpensive. Polyester can be washed and it looks really nice when finished. How much fabric, depends on what size flak vest you will make. You can make a L-XL flak vest out of less than 2 yard of 60" fabric.




Pattern: I made by own pattern out of brown crafting paper. For measurements, I put on my flight suit and measured 1 1/2" from the base of my neck and then measure 3 1/2" up from my belly button. That told me how tall. I then measured my chest size divided by two to get the front and back vest pieces. You do need to consider, if you are using insertion locks on the side, to subtract 3-4 inches. You will also need to add about an inch to the back piece to make it taller. To make the ribbing pattern take your base pattern to Kinko's and have them stretch it 200%.




Hem Base Pieces: After the fabric is all cut out, I sew a 1/4" hem around the 2 base pieces starting at the sides.




Hem Ribbing: The ribbing fabric that covers the base pieces needs to be hemmed at least an inch so you can lay the ribbing fabric on top of the base pieces and have margins on the left and right sides.




Pin the front and back together and draw a straight line across the back using a ruler. It is very important that you keep the lines straight. Sew straight across the line you drew across the back.

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