TM 10-8400-203-23
15-5. REPAIR AND MAINTENANCE OF BODY ARMOR–Continued
Table 15-2. Stitching Instructions –Continued
LOCATION
Overedging ballistic insert
Attach front ballistic fillers to front inner
shells, attach back ballistic filler
assembly to back inner shell, close
neck, attach shoulder pads, attach
ends of side closure to back inner
shell and attach side closure elastic
webs to back of vest.
Join inner and outer shells and catch
side closure
THREAD SIZE
STITCH TYPE
502, 503
504 or 505
301
301
NEEDLE
E
F
F
BOBBIN
E
F
F
STITCHES
PER INCH
6-8
6-8
8-10
d. Outer Shell Replacement. Due to the low cost of the complete outer shell, it is not considered economical
to repair badly torn, worn, or damaged outer shells, including replacement of hook and pile fasteners and
grenade hangers. In lieu, thereof when a vest exhibits large holes or tears, or an outer shell that is severely
worn or soiled, contains inoperative hook and pile fastener, badly torn pocket or pocket flaps, and torn or
damaged grenade hangers, replace the entire shell. The complete shell need not be replaced for tears
less than 1” long or open seams which can be repaired by top stitching. See paragraphs 15-5c and
15-5c(2). Questionable fabric may be tested with a hand pull test, When replacing the outer shell
completely, remove the old outer shell taking care not to damage the Kevlar ballistic filler. After removal,
thoroughly examine the Kevlar ballistic filler in accordance with paragraph 15-5h.
Do not stitch through the Kevlar ballistic filler except where accomplished
in the original construction. If the Kevlar ballistic filler is determined to be
serviceable, attach front ballistic fillers to front inner shells typical left and
right, attach back ballistic filler assembly to back inner shell. The filler
components shall be flat with no puckering. Join inner and outer shells and
catch elastic side closures.
15-8
