Making an RNP (much harder to read than to do)
MEASUREMENTS
My measurements are for a 5β 7β 160# guy.
Measure your vertical distance fingertip to top center of head (call it FTL): Mine = 44β
Length of sylnylon = 2 X FTL: Mine = 2 X 44β = 88β
Width of sylnylon: Mine = 48β You might want more for a really big pack. It will be easy to reduce but not to add.
Measure from the bottom of your earlobe to the top center of your head (call it EAR): Mine = 8β
Length of brow tunnel = 2 X EAR. Mine = 16β
Cord length between anchor loops at ends of brow tunnel when puckered over hat brim: Mine = 9β
MATERIALS
Sylnylon rectangle = 48β X (2 X FTL). Mine = 48β X 88β
Skirt material: Mine = 24β X 50β (comes 12β above the ground)
Cords: (2 mil)
Chin: 30β one cord lock
Nape: 26β one cord lock (perhaps a different color)
Bottom hem rear: 52β 2 cord locks
Bottom hem fronts: (26β 1 cord lock) X 2
Waist: drawstring and cord lock. Mine = 56β
Total, 18β of cord and 7 cord locks.
3/4β velcro: 3β each of hook and of loop.
Optional: additional 3β each of hook and of loop to connect the RNP top to the cap top. See step 11.
Flat synthetic (fusible) 3/4β webbing (for melted holes at mid sides of bottom hem in lieu of grommets): 2β X 2 = 4β (or perhaps use more velcro just as webbing)
Flat 3/16β webbing (perhaps flat shoelace stuff or parachute cord casing) for anchor loops at ends of brow tunnel): 6β
Zipper, single pull, separating. Mine = 29β #5
It should come within 5β of the brow tunnel end loops and not completely reach the hem tunnel. Zippers are measured by length of hardware, not tape length. The space available is (FTL – EAR – 5β – 1 1/2β). Less is ok. Mine = (44β – 8β – 5 – 1 1/2β) = 29.5β
SOURCES FOR MATERIALS
rayjardine.com
thru-hiker.com
DIRECTIONS
It is assumed that the ends of all webbing and cord are fused (melted) to prevent unraveling. The start and end of seams should be backstitched.
1. Sew 1/4β hems on both long edges of the sylnylon. The hemsβ raw edges determine the inside of the RNP
2. Fold the sylnylon in half across its short dimension so that the hem raw edges are exposed, not hidden inside the fold. This fold is the RNPβs top. One pair of the 1/4 inch hems will form the front (zippered). The other pair of hems will form the back seam. Along the same line as the hem stitching sew the back seam from the bottom up to the top fold. The RNP is presently inside out.
Optional: If your tallest pack tops out below head height
shorten the back seam as follows so the RNP does not hang low behind you. Measure the vertical distance from head height to pack top. Call this the DROP. Mark at a distance equal to DROP up from the bottom of the back seam. Draw straight lines from this mark diagonally down to the bottom corners of the front opening and cut along these lines. (I have not done this on my RNP and it works fine but the back hangs low and looks even worse than necessary.)
3. Turn the RNP outside out. Fold a 3/4β wide brow tunnel. The tunnel is to be centered on the front long edge with the raw edge inside the tunnel. this places the tunnel edge inside the RNP. Tunnel length = 2 X EAR (mine = 8β + 8β = 16β ). Sew along the original 1/4β hem stitching.
4. Double over 3β of 3/16β webbing and sew together except for a 3/8β loop at the fold. The top end of this loop is to sit 3/8β below the present end of the brow tunnel. The stitched together tail is to be aligned downward along the (not yet extended) brow tunnel seam.
5. Leave a 3/4β gap in the brow tunnel seam, for access to the loop, and continue sewing the tunnel to the end of the loop webbing (1 1/8β) thereby anchoring the loop in the seam.
Repeat steps 3 and 4 at the other end of the brow tunnel.
6. Sew a 1/4β hem around the bottom, with the raw edge inside the RNP. Starting from the back seam, fold to form the 3/4β bottom hem tunnel. The 1/4β hem raw edge is to be inside the tunnel and the tunnel finished edge is inside the RNP. Sew along the same line as the 1/4β hem.
7. Along the bottom tunnel mark the midpoints between the back seam and the front opening. Center on this mark a 2β length of 3/4β webbing inside the RNP and covering the tunnel (hide the hooks or loops against the tunnel if using velcro but these instructions will still refer to it as webbing to distinguish it from other velcro.). Sew 2β along the tunnel stitching to fix the webbing parallel to the tunnel. Sew the lower edge of the webbing through the tunnel. Do not sew the webbing ends. The tunnel must continue under the webbing (although constricted). Repeat on the other side.
8. Sew the 3β velcro strip (loops) in a similar alignment along the bottom tunnel but ending at the vertical front edge. The velcro will run horizontal (loops exposed) and end at the zipper opening. Sew the lower edge of the velcro through the tunnel. Do not sew the velcro ends. The tunnel must continue under the velcro (although constricted).
9. The 3β velcro strip (hooks) is to have only have 3/4β of its end similarly sewn onto the opposite vertical front edge so that its hooks will engage 2 1/4β of the loops. Do not sew the velcro end. The tunnel must continue under the velcro (although constricted). The velcro will hold the two vertical hems just touching. The zipper will be sewn under the touching vertical hems.
10. Sew the zipper inside the RNP. It must start above the bottom velcro and reach to 5β below the brow tunnel loops. The zipper pull is to be operated from inside the RNP. The 1/4β hems are to just touch outside over the zipper teeth.
11. An optional 3β strip of velcro (hooks) on top of head is centered 6 1/2β behind edge of brow tunnel and inside. The mating loop velcro is sewn crosswise on the cap to make connecting easy. A big wind inflated my entire RNP like a balloon and lifted my cap straight up from my head. The nape cord probably solves the problem but I tried this velcro first and have not experimented without it.
12. The skirt is a tube 50β in circumference with a drawstring at the waist and ends 12β above the ground. Add a rear slit to above knee level.
An easy alternative is cutting the bottom from a trash compactor bag and punching holes every 2β for the drawstring. It weighs 2 1/2 oz. Ace hardware Storesβ brand is 10 for $6 and odor free.
The first 12 steps complete all sewing. Seam sealing seems unnecessary.
13. Heat a wire or nail or icepick (perhaps on the stove) to melt holes in the webbing patches and in ends of the velcro strips. These holes should be little larger than the bottom hem cord you plan to use so that end knots cannot pull through.
When melting a hole you will pierce the webbing (or velcro) and two sides of the tunnel. You must squeeze the tunnel during the melting so the two sylnylon holes do not fuse together because your cord must have access to the tunnel interior after passing into the holes.
Make 2 holes in each webbing patch spaced to divide it into 3 equal parts.
Make a hole in the hook velcro where it is sewn to the tunnel. Make a hole in the end of the loop velcro where it is not covered by the hook velcro.
14. To insert cords into hem tunnels soften 1/2β of the cord end above a candle flame until it droops and wearing a leather work glove draw and twist the heated end to a point. This is the lead end. It will stiffen somewhat as it cools.
Tie a figure 8 knot in the trailing end of a 26β cord (google knots by name). Starting at a hole in the velcro pass the sharp end through all 3 layers and then loop it back through a single sylnylon layer and into the tunnel. Work it along the tunnel to the webbing patch and out through the single sylnylon layer. Then loop it back through all 3 layers. Pull both loops into the tunnel. The holes through the sylnylon opposite the velcro and webbing are only for passing the cord and serve no further function. The cord does not end up running through them. Apply a cord lock and adjust it so the cord is exactly as long as the tunnel between the velcro and the webbing. Secure with a figure 8 knot and trim and fuse. Repeat for the other front hem cord.
The rear hem cord is the same except it has a cord lock on each end at the webbing.
15. Run the chin cord through the brow tunnel. Fix its length between the loops at the tunnel ends and hence the amount of brow tunnel pucker with sheet bend knots. These are easily adjustable. Keep the ends even and apply a cord lock over both. An overhand knot will suffice to retain this cord lock.
Tie a figure 8 knot in the center of the nape cord and slide the cord lock over both strands. The nape cord simply passes through the center of the sheet bends and is secured with a figure 8 stopper knot. When the chin cord is snug the sheet bends will hold the nape cord.
You are done. Rain? No Problem.