Lunar Outfitters: Making the Apollo Space Suit

by Bill Ayrey

Overview

The design processes behind a giant leap for mankind

Neil Armstrong in a space suit on the moon remains an iconic representation of America’s technological ingenuity. Few know that the Model A-7L pressure suit worn by the Apollo 11 astronauts, and the Model A-7LB that replaced it in 1971, originated at ILC Industries (now ILC Dover, LP), an obscure Delaware industrial firm.

Longtime ILC space suit test engineer Bill Ayrey draws on original files and photographs to tell the dramatic story of the company’s role in the Apollo Program. Though respected for its early designs, ILC failed to win NASA’s faith. When the government called for new suit concepts in 1965, ILC had to plead for consideration before NASA gave it a mere six weeks to come up with a radically different design. ILC not only met the deadline but won the contract. That underdog success led to its greatest challenge: winning a race against time to create a suit that would determine the success or failure of the Apollo missions—and life or death for the astronauts.

A fascinating behind-the-scenes history of a vital component of the space program, Lunar Outfitters goes inside the suit that made it possible for human beings to set foot on the moon.

Product Details

ISBN-13:	9780813066578
Publisher:	University Press of Florida
Publication date:	10/06/2020
Pages:	422
Sales rank:	343,824
Product dimensions:	6.12(w) x 9.25(h) x 0.83(d)

About the Author

Bill Ayrey was a space suit test engineer and company historian at ILC Dover for over forty years. He spent more than 140 hours pressurized in the Space Shuttle EVA suit, testing the many components, during its years of development. Over the past twenty years, he has assisted the Smithsonian National Air and Space Museum in preserving the suits within its collection.

Table of Contents

Contents

Preface

Introduction

Part I. Humble Beginnings

1. School of Hard Knocks

2. Developing the State-of-the-Art Space Suit

3. The Turbulent Years, 1962–1965

4. Second Chances: The Model AX-5L and A-5L Suits

Part II. Building the Moon Suits

5. The Model A-5L Space Suit Contract

6. The Model A-6L Space Suit: Unveiling the First Moon Suit

7. The Model A-7L Space Suit, 1967–1971

8. The Model A-7LB Space Suit: The Next Generation, 1971–1975

Part III. Post-Lunar Missions

9. Skylab, the Apollo-Soyuz Test Program, and Other Development Suits

10. End of a Historic Era

Conclusion: Preserving Our Treasures; The Smithsonian National Air and Space Museum

Acknowledgments

Appendix A: Technical Details of the Apollo Space Suits

Appendix B: Apollo Part Numbers and Serial Numbers

Appendix C: Apollo Contract Details

Appendix D: Astronaut Code Names

Appendix E: A-7LB Suit Plug Loads and Fabric Stresses

Timeline of Significant Events

Glossary

Notes

Further Reading

Index

What People are Saying About This

From the Publisher

“A space suit: a miniature space craft, so well designed for Apollo missions as described in this book. Excellent throughout, so comprehensive, so enjoyable.”—Michael Collins, Apollo 11 astronaut

“This is the story of the ultimate space suit for lunar explorers; a garment that evolved over many years of experiment and development; a garment that protected me five times during extravehicular excursions into the vast unforgiving hazards of space exploration, including three days on the surface of the moon.”—David Scott, Apollo 15 commander

“A unique and comprehensible history of a group of men and women who undertook the challenge to create a space suit that would allow humans to explore another world for the first time.”—Cathleen Lewis, coauthor of Spaceflight: A Smithsonian Guide

“A detailed and engaging account of how a group of engineers and seamstresses from a small company built the first and only suit used on the moon. A remarkable book, indispensable for anybody interested in the Apollo program.”—Pablo de León, University of North Dakota

Editorial Reviews

06/29/2020

Ayrey, a testing lab manager for the textile manufacturer International Latex Corporation Industries, provides a pleasing insider’s look at the space suits ILC constructed for NASA’s Apollo program. He explains that the Apollo space suit grew out of the stiff pressure suits created for early 20th-century pilots who flew unpressurized planes at high altitudes. ILC’s experience making pressure helmets for the U.S. Air Force formed the foundation for its space suit work, but it was sometimes an uphill battle for the company, with its occasionally laissez-faire culture, to fit into NASA’s highly bureaucratic structure. But, Ayrey notes, the dedication and craftsmanship of ILC’s staff meshed well with the attention to detail and fit each suit required. Ayrey’s details fascinate: made from 15 layers of materials, each suit was custom fitted to its wearer, right down to gloves made from molds of the specific astronaut’s hands. Suit testing included an x-ray to be sure no pins had been left behind while the suits were being sewn—a critical suit check still done today. Black and white photos and engineering design diagrams add helpful visual detail to the text. This accessible, anecdote-packed history will please many an astronomy buff. (Oct.)

Publishers Weekly

Ayrey, a testing lab manager for the textile manufacturer International Latex Corporation Industries, provides a pleasing insider’s look at the space suits ILC constructed for NASA’s Apollo program. He explains that the Apollo space suit grew out of the stiff pressure suits created for early 20th-century pilots who flew unpressurized planes at high altitudes. ILC’s experience making pressure helmets for the U.S. Air Force formed the foundation for its space suit work, but it was sometimes an uphill battle for the company, with its occasionally laissez-faire culture, to fit into NASA’s highly bureaucratic structure. But, Ayrey notes, the dedication and craftsmanship of ILC’s staff meshed well with the attention to detail and fit each suit required. Ayrey’s details fascinate: made from 15 layers of materials, each suit was custom fitted to its wearer, right down to gloves made from molds of the specific astronaut’s hands. Suit testing included an x-ray to be sure no pins had been left behind while the suits were being sewn—a critical suit check still done today. Black and white photos and engineering design diagrams add helpful visual detail to the text. This accessible, anecdote-packed history will please many an astronomy buff.”—Publishers Weekly

From the Publisher

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