Hi Dale:
Mike Glavin here with Sierra Designs. I find your thread fascinating, because this is a subject we are attacking with vigor in our development at Sierra Designs.
One thing that caught my eye was the discussion of "breathable", which is NOT the key performance metric for a wind shirt. Air Permeability, measured in CFM via various tests, is the key performance metric you seek. However, above you say 2-3CFM plastic bag. A plastic bag has 0CFM. Gore-Tex is about .1CFM, and NeoShell about .5CFM. Frankly, as we all know, there is not much performance difference between Gore-Tex and a plastic bag as it relates to airflow. And breathability (measured in Moisture Vapor Transfer Rate is not much different either). It is why Gore-Tex, like a plastic bag, is guaranteed to keep you wet when hiking with a pack in moderate temperatures.
So, since the rain jacket is always a performance compromise, the wind jacket ought to be the key piece in the clothing system, not the "hard shell" as has become the norm.
Now, the reason this caught my eye is that 2-3CFM is actually the PERFECT air permeability for a cooler weather wind shirt. We target 3-5CFM for all of our wind wear since we think it is the perfect blend of windproof and permeability that allows it to be worn as a second skin in a very wide variety of conditions.
Two things to note: contrary to popular belief, the most effective place in your layering system to wear your 2-5CFM second skin is very close to the skin, right over the base layer. Common "soft-shell" thinking would dictate taking the jacket off in cooler conditions and adding a layer underneath, but this is actually not what you want to do. You actually want to layer OVER your wind layer, which is counter intuitive, but the works with the evaporative process rather than against it. Like a fur jacket. The intuit still wear caribou fur rather than "performance" apparel for this very reason, the "skin" in near your body with ever more breathable (higher CFM) layers moving further out. Ironically, and this is the best part, they traditionally wore an ULTRALIGHT sealskin or fish skin shell OVER this layer ONLY in wet weather (their ultralight rain jacket/plastic bag compromise piece).
You should check out our new Stow Windshirt. The NEW SD website launched tonight!. This is the baby of Jim Trombly, our Product Director. Jim used to be the Alpine Director at Patagonia and is a Houdini HATER! The Stow uses an amazing fabric that has kiss-coat of PU that gives permanent water resistance (unlike a DWR that wears off). AND it hits our magic air permeability rating of 3CFM.
Finally, I will note that in warmer weather, say 50 degrees or warmer, the second skin needs to have a higher CFM to be comfortable in a wider range of temperatures and exertion levels. Our 3CFM garments are poor bug or sun shirts, for example, in warmer weather. For these a 30-50CFM garment will probably work best for wind, bugs, and sun protection.
Hope you find this useful, and thanks for the intriguing thread……
In addition