Construction of Harnesses

Current fabric, thread, webbing, and trimmings and buckles used in harnesses include:

Materials used in construction are generally classed according to higher technology , availability, and customization.

Hi tech/More Money :

• Spectra webbing, Spectra thread, spectra fabric (bonded and unbonded), occasionally Kevlar      
• Custom aluminum, metal and titanium buckles.

Mid Range tech, moderate price:

• Ballistic Nylon fabric, Stock Aluminum Buckles from alternative sports (eg paragliding, rock climbing etc)
• fabric, nylon bonded thread, nylon trim/bindings.

More common, lower tech, less money:

• Mil spec parachute buckles...generally forged, sometimes stamped.
• Nylon webbing, cordura fabric

Two Basic Design Types

Stunt harnesses in terms of overall design concept can fall into two seperate classes or design theories;

 1) those that rely upon critical use webbing sewn to other webbing to make a final product (the fabric that makes up the vest or shorts etc just act as a carrier for the webbing and should not be relied upon for strength)

2) Stunt harnesses that rely upon webbing and the surrounding fabric as an integral product to make up a total safety solution. That is; the carrier fabric that makes up the body of the harness is of a much higher strength and thus webbing does not neccessarily need to stitched into other webbing to gain the appropriate safety factor.  (eg Spectra can be so strong versus cordura that it can be relied upon soley as part of the engineering of the harness)

Stitching Theory

The stitching of traditional stunt harnesses originated from saddle or leather sewing machines and technique. This was mainly due to the fact that the original materials used were heavier ones like Nylon, Cordura, and layered upon layers.

The mid 1990's first saw the introduction of "climbing sewing" techniques to stunt harnesses. This generally meant the use of "bartacking" in appropriate areas in need of strength in confined areas. Bartacking puts a high stitch count into a smaller area of fabric versus traditional safety sewing (box x, and w-stitches.....like the parachute industry).

Their are pros and cons to both types of stitching for stunt harnesses, and a good harness will use the appropriate stitch in the correct manner in the right place.

Bartacks, while being an incredibly strong stitch with high "lock" potential, does not distribute load forces as well as trad stitching. Traditional safety stitching places the stitch count over a great area, grabbing more fabric...thereby distributing force more evenly. On the other hand, bartacks' highly concentrated stitch strength allows the ability to place more pic points in a tighter area....and lend a more modern look to the product.

Sewing Machines and Testing Equipment Used