TM 10-8400-203-23
Change9 25-11
CAUTION
Do not stitch through the ballistic panel when repairing the outer shell. Remove the ballistic panels prior to
any OTV repairs. The ONLY time the ballistic filler panel can be stitched through is to re-attach the
velcro
attachment to the ballistic panel. When re-attaching thevelcro, ensure it is sewn in the original location.
(2) Open seam and broken stitches in outer shell. When it is necessary to repair an open seam or broken stitch, all
sewing shall be machine sewn. Open seam or broken stitching may be made in all areas of the vest. Stitching
on replacement sections and re-stitching of seams will be the same as the original construction.
(3) Adjust thread tension so that there will be no loose stitching or excessively tight stitching resulting in puckering of
the material sewn. When re-stitching an open seam or when a thread breaks during normal stitching, backstitch
not less than ¾ inch. For stitch type illustrations, see Federal Standard 751 (ASTM D6193). In general, stitching
will be performed with nylon Type 1, Class B conforming to V-T-295. All threads visible on the exterior of the
vest shall be Olive Drab S-1, C.A. 66022. Thread size shall be as specified in Table 25-2.
Table 25-2. Stitching Instructions
THREAD SIZE
Table 25-2. Stitching Instructions
LOCATION
STITCH
TYPE
NEEDLE
BOBBIN
STITCHES PER
INCH
General
301
E
E
8-10
Plate pocket openings
Bartack
B
B
28 per tack
Webbing hangers
Bartack
B
B
42 per tack
Labels, pockets and pocket flaps, hem pencil
pocket
301
B
B
10-12
Velcro
301
B
B
8-10
Ballistic Panel
301
E
E
4-6
301
F
F
6-8
Join inner and outer shells and catch side
closure with ribbon
301
F
F
8-10
Side webbing
Box X
B
B
8-10
Ribbon closure on side
Box X
B
B
8-10
Handle
Box X
B
B
8-10
Webbing ends
301
B
B
8-10
(4) Snaps Fasteners.
(a) Resetting. Reset a loose snap fastener by using appropriate dies.
(b) Removal. Remove a damaged snap by cutting it with a pair of diagonal wire cutters or rippers. Be careful
not to cut or damage the fabric.
(c) Installation. Without damage to the fabric, install the new snap fastener (with proper sized dies) according to
the original construction.
(5) Eyelets. Replace missing, damaged or otherwise unserviceable items with eyelets as specified.
(6) Stitching. Replace stitching in accordance with Table 25-2.
(7) Webbing. For horizontal webbing hangers on front of OTV outer shell, note length of bar tack, perform
specification for spacing which is critical for pocket lacing on easily and properly. Lastly, cut the webbing using
heat so it does not have sharp or burred edges.
(8) Velcro. Replace in fashion similar to original construction with the materials listed in Section III OTV Materials.
Stitch in accordance with Table 25-2.
(9) Fabric. Replace with the fabric listed in Section III. Stitch in accordance with Table 25-2.
