Hi Geoff,
I made and have used a poncho out of a combination of similar materials, first on the CT, and have tested it some since. It works well ime/o, though it suffers from some general weaknesses of ponchos in general.
The main difference is that for this particular piece (from what I was recommending earlier), I was lazy and needed a quick solution at the time, so I bought a silnylon fabric with the least amount of HH that I could find. At the time it was one of Dutchware’s lighter than usual silnylon’s that tested very poorly as far as HH (I think it’s average was around 700 to 800 HH). Then I folded it up and ran it through an un-threaded sewing machine to puncture it. Then sewed to Kite/1443R Kite tyvek at the perimeters except for the bottom. Why I didn’t sew at the bottom, I wanted any water that might potentially get through the first layer, to easily and quickly escape out the bottom, rather than holding it in.
Here’s my project if interested:
https://backpackinglight.com/forums/topic/oddunique-but-very-breathable-rain-gear-system/
Yes, if doing the from scratch route, you have to get the coating thickness and initial fabric breathability right. Too thick of a coating or too tightly woven and it becomes too unbreathable, and too thin of a coating and not enough DWR and/or too loosely woven and not enough water resistance.
You could also combine an already EPIC treated fabric with the Tyvek, provided that the EPIC has enough breathability to begin with or is light enough (some of them are rather low breathability and/or are heavy).
Both silicone and Tyvek are subject to oil contamination/accumulation, unlike PU coated or lined PTFE membranes.
That is why I said that very occasionally, you need to give such systems a good degreasing with hot water and a good detergent soap (and then rinsed very well after). That will help to “refresh” the built in, near permanent DWR of both the silicone coated nylon (or polyester) and the Tyvek PE material.
Still cheaper, easier, and more environmentally sustainable than buying DWR’s and retreating fabrics. And more importantly, you can go much longer in between “refreshings”, unlike with most other applied DWR’s.
I will have to look around some for Nisley’s recommendation. I use to have it book-marked on my old lap top, but not this one. Meanwhile, if you type in Richmond Nisley and something like thinned silicone or Richard Nisley+silicone+mineral spirits+weight+ratio into a BPL search, you may find it before I. (As a note, I prefer naphtha to mineral spirits–evaporates more quickly).
That is just a starting point though. I always recommend experimenting a little with ratios, especially since it’s for a different purpose. Nisley came up with his recommendation based on retreating silicone coated WP fabrics. This might suggest or imply, that one could go a bit thinner/lighter, since we are not looking for WP level HH. We are looking for an HH from around 350 to 600 or so. Enough to stop the majority, but not all of the initial force and penetration of the raindrops.
The one main issue and problem with this particular system, is that Kite/1443R Tyvek is NOT a consistent product apparently. It varies somewhat widely as to air porosity. However, I doubt it’s ever too completely unbreathable or too completely porous for this purpose.
If that is a concern though, there is no reason why one can’t combine two silicone treated fabrics. I would actually recommend using two lightweight, breathable, uncoated polyester fabrics treated with thinned silicone. Â
The nice thing about this system is that it doesn’t need to be super exact, because when you combine the HH of two different layers, you get more HH than just adding up their respective HH’s. It’s non linear like that, vs say a single layer of fabric where you do indeed need to get the coating exactly right in order to get a truly waterpoof fabric.
That is what Paramo, the US military, Buffalo systems, etc. rely on. Two moderately to highly water resistant fabrics and in combination with body heat. Shrouded behind marketing glamour, lingo, secrecy, etc.
Â