Thinking muskratsteve had a neat idea, I swung by my local safety supply store. I wilted in the Tyvek suit – too sweaty to imagine working hard while wearing it. I asked the sales staff about alternatives with attached boots that might not be in the show room. They brought me a Kimberly-Clark dust protective suit – Kleenguard A20. Much cooler than the Tyvek. Blowing at it, I felt air go through. Not a good sign, but for less than $7 still worth a try. I bought a 2xl for enough room to move easily in street clothing with pockets loaded for an after-work float.
My test was water in a glass, rubber band sealed to a layer of fabric inverted on a paper towel. Every hour and a half I rubbed the fabric to induce leakage. At 9 hours with no leakage (occasional signs of light condensation appeared on the towel, but the fabric stayed dry) I quit and emptied the glass. When tested across a seam, leakage occurred, but not that all much. The suit exceeded my fondest dreams. I decided I probably had blown across a seam in the store.
The suit weighs only 7 ounces in 2xl. The zipper needs taping to the waist for adequate protection – it would be a sieve If it were not sealed. The neck and sleeves will not seal, so the top of the suit does not count for much. Cutting the coverall into a high suspendered pant would save weight and bulk; sealing the seams would be easy. The pant would couple well with a spray or dry top to protect one on a trip – for 5 ounces or less.
I’ll pick up 2 more suits, sized differently, for serious use. Thanks, muskratsteve for the wonderful idea.