TM 10-8400-203-23
Change9 25-9
Section II. REPAIR PROCEDURES
25-4.
MATERIALS
a. General. Materials used in repair of vests will be new materials as specified in Section III. New materials will be
requisitioned from stock under the national stock numbers and for item descriptions as listed and will conform to the
appropriate specifications. When not available from stock, materials may be purchased locally that conform as closely
as possible to the standard material for emergency repairs. Care and cleaning shall be done by the individual user.
All other maintenance should be accomplished at Intermediate level Maintenance Activities.
b. Fusing of ends of nylon webbing and tape. All ends of nylon webbing and tape shall be fused. The apparatus used to
fuse the webbing and tape ends shall be capable of providing sufficient heat to provide a smooth edge and with the cut
ends of the webbing and tape yarns all fused together. Fusing of the webbing and tape ends shall be accomplished
prior to being assembled for stitching.
25-5.
REPAIR AND MAINTENANCE OF BODY ARMOR
OUTER TACTICAL VEST
a. Inspection.
(1) Inspect the overall condition of the outer shell and components. Check for cuts, tears or holes, loose or broken
stitching, or broken buckles or snaps. (Army) The outer tactical vest should be carefully examined to determine
whether it is worthy of cleaning and repair or whether it must be turned in for salvage as unserviceable.
(2) Each outer tactical vest will be inspected to determine the proper supply condition code classification in
accordance with chapter 1, paragraph 1-7, and identification (item description, size, and stock number).
(3) Prior to the removal of the outer shell for replacement, inspect the outer shell to make sure that the identification
labels (size and stock number) are secure and/or the markings are legible. If the OTV cannot be identified as to
size, refer to table 25-1 to determine the size. If the outer shell is to be removed and replaced, it is important that
the label containing the size, stock number and cleaning instructions be retained for stitching to the new shell. If
the label is unusable, replace label entirely. The ballistic panels should be checked to insure that the sizes are
marked and will be retained.
Table 25-1 Interceptor Body Armor Measurements +/- ½ Inch
CHARACTERISTIC
X-SMALL
SMALL
MEDIUM
LARGE
X-LARGE
Chest Width; IN
23.25
24.25
26.25
28.25
30.25
Center Front Length; IN
17.5
17.75
18.25
19
19.75
NOTE
One-half chest width is measured from the top of each side-opening flap in line with the bottom of the
armhole and across the chest. The measurement is taken by fully loosening side buckles and measuring to
and from side finished edgeat second row of webbing below armhole of the vest at the base of armhole
level. Center front length is taken from a straight line along the front snap closure.
(4) Ballistic Panel Inspection.
(a) (Army) Carefully examine the ballistic panel for any damage. (Marine Corps) Carefully examine the ballistic
panel for any damage prior to each field revolution. If the panel has been ballistically or physically damaged
in any manner such as evidenced by a hole, or cut; do not repair. (Army) Mark the item as unserviceable.
(Marine Corps) Return the item to the manufacturer.
(b) Inspect the ballistic panel to ensure the identification label is secure and/or the markings are legible.
b. Cleaning Instructions.
(1) Outer Shell.
