Recently using a vbl liner with much success in a 3 layer (wool liner/NRS sock/ thick wool) gtx winter boot setup has me interested in using more Vbl in my winter ski-touring sleep kit.
The practicality of a vbl suit over a vbl bag led me to using a sylnylon raincoat for the top, plastic bags for feet (letting NRS socks air out overnight). I just needed a vbl pant layer.
At home depot I saw 1.5 mil. 'extra tough' wind film by Duck brand. Using the same brand of clear window film tape I decided to make some vbl pants.
I used a pair of sweat pants folded to show the 'j' shape in the groin as a template.
I cut through 4 layers of polycro and then used the sweat-pant model to rearrange the layers of poly cross so the outer-leg seam folds matched up. This allowed me to only need to tape the inseam and crotch.
First attempt tracing the 32×32 template resulted in pants that were way too tight. I did add 6 inches to the length of model. I cut a second pair adding as much width to the template as the 66" sheet would allow.
This pair fit with room to squat and move. The tape was applied on both sides on the crutch seams and seems to withstand repeated crumpling and the little use I've given around the house. Draw cord waist band and then elastic bands on sock/pant gap.
Weight seems to be around 3 oz. on large scale. 2 x 4" roll when packed. $5 cost/ pair. Cheap, fun to build, and light; I just hope it proves strong enough to last through real ski tour use. Though, I do only intend to use around camp at the end of the day and when sleeping.
