FABRIC
Burgundy jumbo spandex = 3 yards
Beige jumbo spandex = ½ yard
The original jumpsuits were actually double-layered; if you wish to accurately replicate the weight and thickness of the screen-used uniforms, you’ll need twice as much fabric yardage.
Starbase 375 Logistics offers an excellent fabric bundle for this uniform:
Black jumbo spandex = 1 ½ yards
Although the side stripes are only 4” wide (including allowance), unfortunately you need 1 ½ continuous yards.
On the bright side, this is enough for multiple jumpsuits!
Burgundy heavy knit fabric = ¼ yard
This is for the cuffs at the bottom of the pant legs.
Milliskin spandex = ¼ yard (black for enlisted, red for trainee)
This is for the jumpsuit collar and cuffs.
For enlisted black, I suggest the milliskin spandex from Spandex World:
And for trainee red, custom-dyed spandex is available on my Tailors Gone Wild web site:
Division-colored wool gabardine = ⅛ yard (4 ½ to 5”)
Custom-dyed wool gabardine in TWOK division colors is available on my Tailors Gone Wild web site:
I also offer custom-dyed cotton twill, as a more economical alternative:
Black felt = ⅛ yard
ACCESSORIES, NOTIONS, SUPPLIES, etc.
2 spools of burgundy thread
(Coats & Clark #7870, “Rustana Red” suggested)1 spool of beige thread
(Gütermann #536 suggested)- 1 spool of black thread
1 spool of “flame red” thread (trainee version only)
(Gütermann #408 or Coats & Clark #2160, “Atom Red” suggested)
Off-white thread = 1 spool
Paradoxically, the beige yoke thread I suggested was a close match to the topstitching on the screen-used enlisted jumpsuit I examined, but it looked too dark on my early replica tests.
Conversely, off-white/cream thread was too bright.
Frank Skony recommended Maxi-Lock #32979, “Tea Rose” as an alternative, and I happily second his recommendation.
Beige metal zipper (26” for men’s, 23” for women’s)
3/32” cord = 3 yards
This is for the piping along the yoke, armscye, and left sleeve band.
Low-loft cotton batting = ½ yard
This will be used to stuff the collar and cuffs.
I suggest using Pellon “Nature’s Touch” or “Warm and Natural” cotton batting.
Red ¾” hook-and-loop tape = 1 yard
Beige ¾” hook-and-loop tape = 1” (optional)
Black ¾” hook-and-loop tape = ⅛ yard (enlisted crew only)
2 hook-and-eye closures (ideally size 3)
Three silver or black snaps (ideally size 3)
¾ yard of 1” non-roll elastic (optional)
This is for the elastic “stirrups” on the lower pant legs.
Piping/zipper/edging foot
