Re: [CF36] Converting rig
"... Also, I know people who make harnesses with E thread zigzagged super tight. I wouldn't say I recommend it, but it has been done and jumped several times...
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Circa 1990, Sandy Reid certified the Flexon harness sewn mostly with bar-tacks. Most of those bar-tacks were 3 inches long!
Only the Flexon shoulder joints (directly below the 3-Rings) were sewn with 5-cord.
Flexon was the first American harness with hip and chest rings and it survived all the heavy-weight and high-speed drop-tests required by FAA TSO C-23C.
The only problem was that bar-tack machines were not durable enough for sewing harnesses year-in-and-year-out. .. which is why Rigging Innovations had switched to sewing most of their harnesses with 5-cord by the time I started working there in 1994.