How to Make a Fire Suit

Fire suits are used for auto racing and other high-intensity sports or activities where there is a risk of being exposed to extreme heat. Racers, military pilots and astronauts wear suits made from futuristic materials such as Nomex or Kevlar, which are both designed to offer protection from fire -- although Nomex is typically used for this purpose. The fabric is a polymer that is sold in sheet form or as a bulk fiber, available for purchase online. Hoods made of this fabric are worn by firefighters over their facial masks, to protect them on the job.

Things You'll Need

  • Nomex fabric
  • Nomex zippers and thread
  • Nomex elastic
  • Pattern for coveralls and a hooded jacket
  • Tailor's chalk
  • Scissors
  • Straight pins
  • Large safety pin
  • Sewing machine
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Instructions

    • 1

      Choose a pattern for a one-piece coverall and a long-sleeved jacket with a hood.

    • 2

      Take measurements of the person for whom the fire suit is being made.

    • 3

      Lay out the pattern for the one-piece jumpsuit, and measure it to make sure it matches the measurements of the person. Mark the correct measurements on the pattern, using tailor's chalk.

    • 4

      Cut out the pattern according to the directions and based on the person's measurements as marked.

    • 5

      Fold the fabric inside out with the finished edges meeting, and lay it out on a flat table or counter.

    • 6

      Pin the pattern to the fabric according to the diagram suggestions in the pattern package.

    • 7

      Cut out the fabric along the edges of the pinned pattern where it's marked.

    • 8

      Remove the paper pattern from each cutout, and pin the pieces of fabric together, inside out, according to the directions provided in the pattern.

    • 9

      Stitch the pattern pieces together on your sewing machine, with the Nomex thread.

    • 10

      Cut out and sew the pattern for the jacket, as you did for the coveralls.

    • 11

      Turn up the hem on the pants and on the ends of the jacket sleeves, leaving an open pocket to insert the elastic. Stitch the hem by hand or on your machine, with Nomex thread, making sure to leave an opening in the seam for the elastic.

    • 12

      Attach a large safety pin to the end of the Nomex elastic, and thread it through the hems on the pants and jacket sleeves. Check the length by trying on the clothing items, and cut the elastic when you're sure of the correct fit around the ankles and wrists. Stitch the ends of the elastic to secure it. Stitch the remainder of the seam in the pants and jacket where you slid the elastic.

    • 13

      Sew the Nomex zipper to the jacket, according to the directions supplied in the pattern.