Step 1: Choose Your Template and Materials
For template I went with a front and back “Flap” which would be connected using plastic buckles.
For materials I used:
1.5 yards of Duck fabric (60D Nylon with PVC coating)
Roughly 300 inches of Nylon webbing/straps (About 25 feet)
1/3 of a cheapo camp mat (Any sealed foam should work. Open foam will absorb sweat and begin to mold/breed bacteria)
8x Male buckle (Three pronged end)
Step 2: Cut Your Template
Cut out your template using very sharp scissors or a razor blade.
Step 3: Mark Your Cuts and Stitches
A solid line grid works best for defining where MOLLE webbing will go and it helps dramatically when it comes to stitching in straight lines.
Start at the bottom of your grid and work side to side. With a sewing machine this will “Feel” like you are working the material “Backwards” as you work to the top.
I used a heavy linen/ light curtain material to back the duck fabric, thus reinforcing the embroidery stitch.
I Anchored the middle and ends of each strap with a thicker embroidery stitch and used a thinner embroidery stitch in between. This helps add strength to the garment the same way a “Double stitch” would.
I use the embroidery stitch as it will move with the fabric. Rule of thumb, a longer or thicker stitch will take more stress before breaking. I tested this with a piece of canvas and nylon webbing using a short stitch. It took over an hour to stitch a 12″ x 12″ grid of nylon webbing, it took less than 2 minutes to rip all of the webbing off of the canvas fabric using moderate “tugging”.
Tip: Test the strength of your projects as you do them, the earlier you catch a weakness, the less time it will take to correct the problem.
Step 4: Stitch the Webbing
Start adding the webbing. I went with a 12 / 8 / 12 / 8 / 12 / 8 / 12 / 8 / 0 / 8 / 0 / 8 / 0 / 8 slot configuration to give versatility and openings on the vest to add the necessary attachments.
Step 5: Prepare Your Connection Attachments
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These attachments will make it possible to secure the front and back “Flaps” to your body. They need to be strong enough to support all of your gear and then some.
Step 6: Add a Hydration Pocket
Adding a hydration pocket is easy. Just cut out a shape larger than your water bladder and add it to the other side of the “Flap”
Step 7: Finish Up
Stitch together the inside and outside pieces of the “Flap” or bind them with Nylon straps for a more finished appearance.