Making a custom BC for ST Forum member "Dagrath".

[ScottZeagle]

"Dagrath" and his buddies ordered a few custom Brigades, so I figured I would snap a few photos and run through the BC making process for you guys...

The order was originally for an all green BC, but after I discussed the green options we had available with him, the guys decided to go for a bright neon yellow, so that they would really stand out.

The only suggestion I made was to keep the waist panels black, so that the BC would have some contrast.

The BCs hit the factory floor this morning, and I took some photos so you could all follow the flow.

First, the material is layed out and the patterns are marked:

[ScottZeagle]

Next, all the BC pieces are put into a Zeagle box and make their way through the various sewing stations. The box that the pieces start out in will be the same box that the finished product is shipped to the store in.

Here is the vest section of the BC as it starts its trip through the sewing floor:

[crgjpg]

Would it be possible to show the whole process in pictures or a video? Is it possible to get an actualy tour?

Note: OK, I was too quick. More pictures posted after I posted.

[ScottZeagle]

And at the first sewing station:

[Jenn]

That's pretty cool I had no idea that you can have a custom bc made. I will have to look into that when I am ready for another bc.

[ScottZeagle]

After all the parts go throught the initial sewing station, they are serged, and when they are done the BC starts to take shape:

[ScottZeagle]

The BCs made it through the serger today and here is how they sit now:



More pictures tomorrow, as Dagraths custom BC makes its way toward completion!!!

[pir8]

cool!!!

[dagrath]

Very, very cool! Thanks so much for posting the pictures.

We are all super excited to get them, and then go diving!

[ScubaJ]

Like our very own "How it's Made" show. Very cool Scott. Thx for sharing it with us. We promise to keep all trade secrets safe within the ST family.
Neat to see the process our Brigades went through.

I've always wondered why the industry moved away from the neon colors toward black. Black looks cool on the surface, but is much harder to spot underwater, making rescue operations and keeping track of your buddy harder. Especially in the swamp I dive (Lake Travis TX).