I know. I mentioned your plans and the Packa somewhere early in the thread.
I have gotten as far as finding a sewing machine that I could use. Haven’t figured out how to string it yet. Or with what.
Even if I do, I have it on good authority that sewing is a craft. Hence my preference for gear made by a suitably experienced craftsman/person/thing. Which is why it would be cool if you would start a company, or at least license out your designs. I suppose that would mean less time in the Pyrenees though. Tradeoffs.
I think I’m pretty far away from making a shirt. Or a mountain poncho. Those hood instructions make me think about wearing a hat instead.
Packa could be a possibility. Not yet sold on its sleeves/weight/fabrics. I don’t currently spend much time above treeline, so not sure that I need all that. A regular zippered poncho might better fit my use case.
The shirt actually seems like the more important (and elusive) part of the system.
In the meantime, I plan to see what I can accomplish with fabric that does not require those folded-up edge things. What do you call them? Seams? Gonna try scissors on my Frogg Toggs poncho with Gorilla Tape reinforcements and snaps for my first attempt. Maybe elastic and clips if I get fancy.
IFF I ever develop any skill at all, then I suspect that I would put it to use on a multi-zoned garment. I kind of like Justin W’s concept. Wish I could find his old thread. I may just have to post my thoughts about it here. It is off-topic from Robert’s original question, but I guess the thread has wandered around a bit anyway.
I’m thinking that I don’t NEED a poncho if I could fix the usual problems with a rain jacket. Like removing the back completely, or using some kind of breathable mesh/monolite/Capilene-like stuff. Torso zips (like OR Foray) that open around the pack’s shoulder straps might solve the front problems. Shoulder and arm tops are the only part that need to be waterproof (maybe hood if used). The rest could just be tightly woven windshirt material. The vertical parts don’t need to be highly waterproof except in high wind. (The main advantage of a jacket is that it is easy to take the pack off.)
But that seems like a lot of work, and my front-zippered poncho has been fine so far.
A Hoody Pack Cover (HPC) over a windshirt could be an off-the-shelf zoned solution. Maybe I could talk LightHeartGear into adding zoned sleeves: Waterproof on top, breathable on the bottom?
Still, though, I keep coming back to the Taslan shirt as the primary puzzle to solve, because that is the most-used part of the system, isn’t it? None of the usual windshirts breathe as well as I want. My Ferrosi soft shell does, but it is too much for Summer rain. I need something lighter. My best candidate for a Summer windshirt is a Columbia Silver Ridge Lite PFG shirt. It is mostly a polyester sun shirt, but I recently discovered that it is a credible wind shirt as well. Over a Summer-weight base, it is good down to 40F/5C while hiking with a pack. Not quite as versatile as your shirt, but maybe as good as I can expect to find. Between the Silver Ridge and the Ferrosi I can cover a very wide range of conditions.