Figure 5-88. Lines are taut in the center.
Figure 5-91. Packing paddle at 1⁄3rd location.
Figure 5-92. Creating the “S” fold.
Figure 5-89. Fold tail back for wind channel.
Figure 5-90. “S” fold drawing.
11. Pull the top center cell panel down to the bottom of
the stack.
12. Wrap the center cell around the folded canopy with the
left and right about halfway to the center, then secure
with clamps starting at the bottom. [Figure 5-93] The
width of the folded canopy should be the width of the
D-bag plus 2 inches (5cm).
13. Continue to wrap the center cell around the canopy
stack and secure with additional clamps. [Figure 5-94]
Step 5. Placing the Canopy into the Deployment Bag and
Stowing the Lines
1. Lift the base of the folded canopy and slide the reserve
bag underneath. The grommets in the tongue of the
bag should be even with the bottom of the stack.
[Figure 5-95]
2. Make a second “S” fold to match Figure 5-96.
3. Split the loose fabric at the top to form two “ears.”
[Figure 5-97]
4. Gather the center cell material along the middle seam
until you reach the bottom. Roll the material under,
but do not cover the center cell. [Figure 5-98]
Figure 5-93. Wrap tail, two clamps.
Figure 5-94. Finish wrapping tail, four clamps.
Figure 5-95. Bag positioned under canopy.
Figure 5-96. Second “S” fold.
Figure 5-97. Split fabric and form “ears.”
5. Hold down the center cell material and then shape the
molar folds. [Figure 5-99]
6. Fold the ends of the molar folds under to create
the bulk necessary to fill the top of the reserve bag.
[Figure 5-100]
7. When placing the canopy in the bag, allow the
folded canopy to stick out 2–3 inches at the mouth
of the bag to fill the corners of the reserve container.
[Figure 5-101]
8. Close bag and secure with the locking stows.
[Figure 5-102]
9. Shape the bag. The shape of the bag should reflect the
desired shape of the reserve container.
10. Cover any exposed hook Velcro ® to avoid contact
with the lines.
Figure 5-98. Gather and roll center seam fabric.
Figure 5-101. Place canopy in bag.
Figure 5-99. Shape molar folds.
Figure 5-102. Close bag and secure locking stows.
Figure 5-100. Fold molar ends under.
11. Stow the lines neatly leaving sufficient line between
the bag and riser ends. [Figure 5-103]
12. Thread the pull-up cord through the closing loop.
Step 6. Placing the Bag into the Container and Closing the
Container
1. Place reserve risers into the pack tray. Spread the risers
with the rear riser to the outside to minimize the bulk
against the back pad. [Figure 5-104]
2. Place the reserve bag into the container and S-fold the
bridle in the center of the bag. [Figure 5-105]
3. Fold the top yoke portion of the bag over the bridle.
[Figure 5-106]
4. Secure in place with a clamp. [Figure 5-107]
Figure 5-103. Stow lines.
Figure 5-106. Fold the yoke over the bridle.
Figure 5-104. Place risers in the pack tray and spread.
Figure 5-107. Secure yoke/bridle with clamp.
Figure 5-105. “S” fold the bridle on bag.
Figure 5-108. Gun rod through the pilot chute.
5. Use the gun cleaning rod to thread the pull-up cord
through the pilot chute. [Figure 5-108]
6. Center the base of the pilot chute on the center
grommet of the deployment bag.
7. Compress the pilot chute while stuffing fabric and
mesh between the spring coils.
8. Position the cap of the pilot chute with the
arrow facing toward the top or bottom of the
container. [Figure 5-109] Secure with a temporary pin.
9. If an AAD, such as a CYPRES ®, is installed, route
the pull-up cord through the cutter first, then through
the right (#1) side flap grommet. [Figure 5-110]
Figure 5-109. Position pilot chute.
Figure 5-110. Route pull-up cord through cutter and right flap.
Figure 5-111. Close right and left flaps simultaneously.
Figure 5-112. Close #3 bottom flap.
10. Next thread the left (#2) side flap grommet. At the
same time, close the side flaps. [Figure 5-111] Secure
with a temporary pin.
11. Close the bottom flap (#3) and secure with a temporary
pin. [Figure 5-112] NOTE: At this point, you should
only be able to pull 1⁄4–1⁄2 inch of loop through the first
three flaps. If you can pull more, the loop is too long.
Open container and shorten loop.
12. Close flap #4 and insert the ripcord pin.
[Figure 5-113] CAUTION: Place the closing plate on
the bottom edge of the inner top flap. This protects the
plastic stiffener if you are kneeling on the pin protector
flap. The rigger should determine how tight the closing
loop is and decide whether to perform a pull test.
Warning: Maximum allowable pull force on the
reserve ripcord is 22 pounds (10 kg).
13. Once you are satisfied that the pull force is less than 22
pounds (10 kg), seal the ripcord and log the pack job.
14. Place the data card in the data card pocket. [Figure 5-114]
15. Count your tools.
16. Complete the placard data on the orange warning label.
Failure to do so voids the TSO.
Figure 5-113. Close flap #4 and insert ripcord pin.
Figure 5-114. Place data card in pocket.
Figure 5-115. Set brakes. Excess lower control line is inserted
through top of riser, around nose of toggle, and toggle placed in
nose keeper.
Figure 5-116. Four-line (separate the line groups).
Ram-Air Reserve into a Two-Pin Piggyback
Many sport, military, and pilot emergency rigs feature the
two pin, externally-mounted reserve pilot chute or Pop-
Top. The Pop-Top closes use adjustable closing loops that
are tightened after the pins are inserted. The following
instructions demonstrate the PRO pack method without the
use of clamps. [Figures 5-115 through 5-165]
Figure 5-117. Push the slider up to the slider stops.
Figure 5-120. Split nose of canopy; three cells to each side, exposing
center cell.
Figure 5-118. Flake the nose cells of the canopy.
Figure 5-121. Sweep arm underneath flaked canopy and gently lay
it on the floor.
Figure 5-119. Hold all flaked nose cells between the knees. Reach
down and flake out material between A/B, B/C, and C/D lines.
Documentation
One of the most important parts of the packing process is the
requirement to keep proper records. 14 CFR part 65, section
65.131, specifies the information the rigger is required to
document. There are two forms of required records. The
first is the rigger’s logbook. While the exact format is up
to the rigger, there are commercially-produced logbooks
Figure 5-122. Pull up and smooth out the top skins of the canopy,
cleaning up between the folds.
Figure 5-125. It is important to equally divide the canopy and
maintain that division throughout the pack job.
Figure 5-123. Pull the lines taught and to the center. Figure 5-126. Tuck the slider up between A/B and C/D line groups.
Some manufacturers recommend stowing the apex of the slider with
a rubber band to the center B or C line attachment tab (whichever
one it best aligns with).
Figure 5-124. If the PRO packed canopy was laid down carefully,
it will be essentially flaked. Only minor straightening is necessary.
Figure 5-127. Narrow the pack job by folding the divided sections
in half. The sections can be folded under or up.
available that provide space for the required notations. The
second required record is the parachute data card. Both of
these items have been addressed in Chapter 1, Introduction
to Parachute Rigging.
Figure 5-128. Without disturbing the rest of the folds, pull the center
tail section down to the slider grommets.
Figure 5-129. Cocoon the canopy by wrapping the tail around and
under. The nose is splayed out with three cells to the right, three
cells to the left, and the center cell in the middle.
Figure 5-130. Accordion the center cell, dividing the canopy in half.
Weights can be used to control the pack job.
Figure 5-131. Two packing paddles can be used to make a neat
S-fold.
There are several items of interest regarding the parachute
data card. In the past, the data cards usually had information
only for the identity of the parachute canopy, which is the
primary component of the assembly. In recent years, with
the growth of sport parachuting, this configuration is no
longer standard. With the proliferation of many makes and
models of canopies, harness, and containers, and the ability
to interchange components, it is necessary to document the
harness and container as well. The data card shown in Chapter
1, Figure 1-8 has multiple identification spaces. With the
widespread use of AADs, it has now become necessary to
document the information required by the manufacturer such
as the service cycle and battery life. The newest cards have
provisions for this information.
With the ability to interchange components, what does
the rigger do when a reserve canopy is removed from an
assembly? Where does the data card go? This is a somewhat
gray area, but the common practice is for the card to remain
with the canopy. If the harness and container have had work
Figure 5-132. The length and width of the S-fold is determined by
the width of the container and the distance between the main/reserve
vertical partition and the bottom flap grommet.
Figure 5-135. Inside the Reserve Speed Bag the buffer tabs form a
clear channel for the bottom closing loop.
Figure 5-133. Make a second S-fold with the upper part of the
canopy on top of the lower part.
Figure 5-134. Prepare the Reserve Deployment Speed Bag by using
a hemostat to pinch the inner buffer tabs together as shown.
done that requires documentation, it may be necessary for
the rigger to fill out a duplicate card with the appropriate
notations as to the work done on the harness. Riggers should
make sure that they note that this card is a copy of the original.
Finally, riggers are tasked with noting their name and
certificate number on the data card. In many cases, this
information is illegible. Riggers who take pride and
responsibility in their profession and the work they do have
no hesitation in letting the public know who did the work.
Accordingly, many riggers have a permanent ink stamp with
their name, certificate number, and seal symbol that they use
to stamp the card and then countersign it. This is the mark
of a truly professional rigger. While the seal symbol is not
required on the data card, it allows anyone to check the
signature against the seal on the parachute.
Chapter Summary
It is the responsibility of the attending rigger to ensure
that the components of the approved parachute system are
compatible in terms of shock load capability. This may be
as simple as reading and comparing the TSO/Data Label
that is permanently attached to the reserve canopy and the
harness. This information may also be found in the respective
Figure 5-136. The S-folds go below the buffer tabs when the canopy
is in the bag.
Figure 5-137. Fold the ears under and pull the bag over the canopy.
Figure 5-138. Use the flaps of the bag to control the canopy and
help push it into the bag.
Figure 5-139. The top flap closes first so that the rubber bands come
through the slots in the bottom flap.
Figure 5-140. Stow the lines from top to bottom. Each stow is a
locking stow.
Owners Manuals. If in doubt, call the manufacturer(s). Size
compatibility, which may affect reserve bag extraction force,
is of the utmost importance. In their zeal to make rigs more
windproof, some manufacturers have created containers that
Figure 5-141. Depending on the length of the lines and the width of
the bag, all of the rubber bands may or may not be used.
Figure 5-144. The second bodkin is now threaded through the bag
in the opposite direction.
Figure 5-142. Insert a bodkin through the channel in the bag where
the hemostats were.
Figure 5-145. A bodkin that has been pre-loaded through the
backpad of the container can now be easily pulled through the bag
using this second bodkin.
Figure 5-143. Pull a second bodkin through the bag using a pull
up cord. Figure 5-146. The bottom bodkin shown in place.
require more force to pull the bag from the container, due
to stiffer riser covers, boxing at the top of the container, and
longer cantilever pin protector flaps. Such rigs should not be
overstuffed. Reserve pilot chutes should be in new condition
to provide maximum drag.
Again, it should be emphasized that the reason for opening
the container every 180 days is to inspect and recertify the
canopy and container system for another 180 days. Recent
language published by the FAA clarifies what the service
life of a parachute is by stating that the rigger may extend
Figure 5-147. Carefully tuck the corners of the bag into the bottom
of the container.
Figure 5-150. Close opposite side flap.
Figure 5-148. Close bottom sub flap.
Figure 5-151. Maintain the division of the canopy by pushing the
ears down and outward. This is where the pilot chute spring will nest.
Figure 5-149. Close either side flap (not side-sensitive).
the life of the system 180 days at a time, so effectively the
service life of any parachute TSO’d under C23b, C23c, and
C23d is 180 days.
Figure 5-152. S-fold bridle and evenly distribute on both sides of
container.
Figure 5-155. Close top (yoke) flap.
Figure 5-153. Insert bodkin through the top grommets of the backpad
and bag and close upper side flap. There should be little or no
canopy fabric in this upper area if good division of the ears has
been maintained.
Figure 5-156. Place pilot chute in depression formed in the center
of the pack.
Figure 5-154. Close other side flap leaving a short section of bridle
below the pilot chute.
Figure 5-157. Thread pull-up cords through each closing loop and
through bodkin eyes.
Figure 5-158. Compress pilot chute tucking fabric and mesh between
the coils of the spring.
Figure 5-161. Pull top closing loop through the grommet and
insert pin.
Figure 5-159. Flip the container over and kneel on it to control
the spring.
Figure 5-162. Pull bottom closing loop through the grommet and
insert pin.
Figure 5-160. Pull the bodkins with their respective pull up cords
through the pack.
Figure 5-163. Pull on running ends of adjustable closing loop to
shorten the opposite loop until pilot chute is sufficiently seated.
Figure 5-164. Insert running ends into the isolated space between
pilot chute “Hat” and top of the spring, using a hemostat or tweezers.
Figure 5-165. Dress per manufacturer’s instructions and attach seal
to the last pin.
Introduction
Riggers are taught that there are three things necessary to do
a proper job: knowledge to do the work, the correct materials,
and the right tools. The job cannot be done correctly without
all three of these essentials. The right tools include various
types of sewing machines, as well as a wide variety of
specialized hand tools.
The importance of learning the names and nomenclature
of rigging tools and equipment cannot be overemphasized.
Just as learning the language of a foreign country allows an
individual to live and operate efficiently within a society,
learning the language of the rigger allows new riggers to
operate and interact within their profession. Without the
necessary vocabulary, a rigger is not able to work with other
riggers and, more importantly, does not present a professional
image to customers. For example, when shopping for tools
or sewing machines for rigging, the same tool may have a
different name when used by some other trade. Knowing the
language of the rigger helps avoid confusion.
Hand Tools, Sewing
Machines, and the
Parachute Loft
Chapter 6
Figure 6-1. Field rigger kitbag with tools.
Hand Tools
A new senior rigger must acquire enough tools to pack and
maintain the types of parachutes for which he or she is rated.
In the course of training, the rigger candidate is exposed to
various tools and individual rigging techniques. Some riggers
adhere to a minimalist philosophy and use as few tools as
necessary. This may initially consist of a packing paddle, a
pull-up cord, and a temporary locking pin, or just a pull-up
cord, when packing main parachutes at the drop zone (DZ).
With some types of parachutes, these may be all the tools
needed to pack them. Other riggers develop techniques that
utilize an array of tools designed to make the job easier or
the end result neater. Some manufacturers have designed
specialized tools to make their particular parachute easier to
pack and maintain. Each rigger develops a suitable technique
and then obtains the tools to support it.
In the past, the list of tools needed to pack and maintain
military surplus parachutes was limited. Since most military
parachutes were simply variants of the same canopy designs,
common tools could be used across the board. In today’s
high-tech world, some of these original tools are still used
along with a number of newer designs. Many riggers and
manufacturers design and build tools to fit a need, whether
it is a new rig design or to make a job more productive.
All riggers need to create a tool kit tailored for their particular
situation. Figure 6-1 shows a commercially-available field
rigger kitbag with tools. Although commercially-made
kitbags are nice, they are expensive. Many riggers are
“weekend” riggers, meaning they have a regular job during
the week and work as a rigger on the weekend. This is typical
of many skydiving riggers. Other riggers work full time in a
loft or manufacturing environment.
Depending on their needs, riggers have different approaches
toward their tools. The weekend rigger may travel to a DZ
where the primary job is packing. Therefore, the tool kit is
more basic as the purpose of this kit is not to take the whole
loft to the DZ. The rigger who works in a full-time loft may
have a more comprehensive tool kit, since it does not have to
be hauled around. For the weekend rigger, there are several
field rigger kitbags available commercially that hold a full
assortment of tools. Many riggers design and build custom
kitbags tailored around their individual requirements. Doing
this is an excellent way to show off sewing skills, while
at the same time creating a needed tool kit. There are also
contractor tool bags made of a strong fabric with many
pockets and compartments that work well with the type
of tools a rigger uses. These bags are inexpensive and are
available at hardware and home improvement stores.
To stock the tool kit, the rigger must determine what tools he
needs. This depends on where the tools are used: in the field,
DZ, or in the loft. Figure 6-2 shows a list of necessary tools
that have been proven useful for today’s rigger. The list of
tools is broken down into two different categories: Category
1, items 6-3 through 6-49 are mandatory tools; Category 2,
items 6-50 through 6-56 are optional tools as most of them
are for use in the loft.
Hand Tools Description
The tool belt is one of the most useful items the rigger can
have. [Figure 6-3] Most tool belts are custom built by the
riggers themselves and include a selection of tools that are
frequently used around the loft. It always seems that the tool
the rigger needs at a particular moment is at the other end of
the packing table or on another sewing machine. The use of a
tool belt makes riggers more efficient as they are not always
looking for and having to retrieve their tools. A well-designed
tool belt holds the following tools as a minimum: scissors,
thread snips, 6-inch ruler, marking pencils and pens, butane
cigarette lighter, seam ripper, Exacto® knife or scalpel, short
packing fid, and finger-trapping needles. Other tools can be
added according to the needs of the individual rigger. The
following is a list of common tools and a brief description
of how they are used.
Seam ripper—used in the sewing industry for “picking”
stitches and ripping out seams. It has a pointed sharp end and
an inside cutting edge for slicing through thread. [Figure 6-4]
Hemostats or clamp—used by riggers for many clamping or
retrieving operations. Two or three sizes should be obtained,
as well as both straight and curved models. These tools can
be found at hardware or auto parts stores. [Figure 6-5]
Scalpel or Exacto ® knife—used for delicate cutting of
materials or thread. The Exacto ® knife is preferred as the
handles come in various sizes and with a wide selection of
blades. [Figure 6-6]
Figure 6-3. Rigger’s tool belt.
Figure 6-4. Seam rippers.
Figure 6-5. Hemostats or clamps.
Figure 6-2. Rigger’s tool list.
Rigger’s Tool List
Figure # Description
6-3 Rigger ’s tool belt
6-4 Seam rippers
6-5 Hemostats or clamp
6-6 Scalpel or Exacto ® knife
6-7 Thread snips
6-8 Butane cigarette lighter
6-9 6-inch stainless steel rule
6-10 Fabric marking pencils & felt tip markers
6-11 Scissors
6-12 Finger-trapping needle
6-13 Finger-trapping wire
6-14 Packing paddles and packing fid
6-15 Pull-up cords
6-16 Locking pull-up cord
6-17 Molar strap
6-18 Temporary locking pins (temp pins)
6-19 Velcro ® line protectors
6-20 Closing plate
6-21 T-bar positive leverage device
6-22 T-handle bodkin
6-23 Pilot chute threading tool
6-24 Pilot chute locking rod
6-25 Line separator (suspension line holder)
6-26 Connector link separator tool
6-27 Shot bags
6-28 Seal press
6-29 Lead seals and seal thread
6-30 Rigger’s logbook
6-31 Packing data card
6-32 Note pad
6-33 Rubber bands
6-34 Hand tacking needles
6-35 Straight & T pins
6-36 Navy end tab
6-37 Waxed nylon “supertack”
6-38 3-cord cotton thread—waxed
6-39 Tape measure
6-40 Shoulder strap hook
6-41 Pony clamps
6-42 6-inch adjustable wrench
6-43 Screwdriver—multi-tip
6-44 Needle-nose pliers
6-45 Cable cutters
6-46 Ripstop roller
6-47 Beeswax
6-48 Spring scale and fabric testing clamps
6-49 Hot knife element w/cutting tip, basting tip, and stand
6-50 Hot glue gun
6-51 Tension board assembly w/apex tiedown
6-52 Size “O” rolled rim spur grommet handset
6-53 Hole punches
6-54 Cutting pad
6-55 Rawhide mallet
6-56 Binding tool
Thread snips—used in the sewing industry for trimming or
“snipping” thread when sewing. Handier and easier to use
than scissors as the point is finer and allows more precise
cutting of the thread. The ergonomic design takes some
getting used to but proves superior in the long term. The
stainless steel models are best, but some riggers prefer the
plastic ones that have replaceable blades. [Figure 6-7]
Figure 6-6. Scalpel or Exacto® knife.
Figure 6-9. 6-inch stainless steel rule.
Figure 6-10. Pencils and felt markers.
Figure 6-7. Thread snips.
Figure 6-8. Butane cigarette lighter.
Butane cigarette lighter—used for burning thread ends to seal
the thread and keep stitches from raveling. It is also used for
searing tapes, lines, and light webbing. One of these should
be at each sewing machine or work site so the rigger does
not have to leave the work to find one. [Figure 6-8]
6-inch stainless steel rule—used for making fine measurements
during work. At a minimum, the scale should read to 1⁄16 inch
and have a dual (English/metric) readout. Certain models
have one rounded end. This model can be used for removing
cut stitches from work by rubbing the rounded end against
the thread thereby lifting it and making it easier to remove.
[Figure 6-9]
Fabric marking pencils and felt tip markers—used for
marking webbing, tapes, and fabric. The Dixon #134s was
used in the parachute industry for decades but is no longer
available. The Dixon China Marker is now used by many
riggers, as it contains no acid, and they come in 12 colors.
Other types have been found to contain abrasives and
compounds that, when used on canopy fabric, weaken the
material. This particular brand of pencil has been found to
have minimal effect on the fabric. Various colors, such as
white, yellow, and red, are useful. Fine point felt tip markers
are used for marking certain materials, such as Dacron ® or
Spectra® line. Black, red, and blue are most common. Felt tip
pens, such as Sharpie® and Pilot® ultra- fine point permanent
type, are used by many riggers. [Figure 6-10]
Scissors—used for cutting all types of materials used in the
parachute industry. A high-quality scissor is lightweight,
ergonomic, and comes in right-hand and left-hand models.
Also, a short 5-inch barber shear is very sharp even when
“used” and works very well in cutting Cypres loop cord and
other line material commonly used in parachute rigging.
[Figure 6-11]
Finger-trapping needle—used for inserting suspension
line into a “finger-trap” configuration. It is a heavy-duty
threaded needle commonly called a “fid,” not to be confused
with a “packing fid” or “paddle.” Plastic ones are available
commercially, but the best ones are custom made from
stainless steel or aluminum knitting needles. Cut to length,
they are then drilled and tapped with screw threads in the
flat end. The size 2, 6, and 8 needles are the most popular
for the current line sizes. A blunt end needle is also used to
finger trap Cypres loop cord. [Figure 6-12]
Figure 6-11. Scissors and barber shears.
Figure 6-12. Finger-trapping needle.
Figure 6-13. Finger-trapping wire.
Figure 6-14. Packing paddles and packing fid.
Figure 6-15. Pull-up cords.
Finger-trapping wire—used to finger trap line too small to
use a needle on. It is made from a wooden or plastic dowel
with a wire loop made from safety wire. [Figure 6-13]
Packing paddle—used for dressing the pack of the parachute
when packing. This tool is made from either wood or
aluminum. The MIL-SPEC paddle has rounded ends and
is 1 9⁄16" × 12" long and tapers in thickness from 1⁄4" to
3⁄16". The wooden commercial paddle is 1 3⁄4" × 15" long.
[Figure 6-14A]
Packing fid—similar to the packing paddle, used also for
dressing the parachute pack and tucking in flaps. The fid is
approximately 19⁄16" × 8" long and tapers from 1⁄4" to 1⁄8". It
is made from aluminum and was originally a United States
Navy tool. Many riggers have both the fid and the paddle,
but usually develop a preference for one or the other.
[Figure 6-14B]
Pull-up cords—used to “pull-up” the locking loop of
parachute containers when closing and pinning them. They
are made from lengths of suspension line: Cypres loop cord
or Type-3 tape. [Figure 6-15]
Locking pull-up cord—used to lock the thickness of a two-
grommet reserve deployment bag when packing the reserve
canopy. It is made from 72 inches of red Type-3 suspension
line and a size 94 Cordlok nylon fastener. It may be used on
one-pin or two-pin reserve bags. [Figure 6-16]
Molar strap—used to control the folded reserve canopy prior
to inserting it in the reserve free bag made from Type-8
webbing and a Camlok nylon buckle. The webbing should
be at least 48" long and brightly colored to serve as a flag
against leaving it on the canopy. [Figure 6-17]
Figure 6-16. Locking pull-up cord.
Figure 6-19. Velcro® line protectors.
Figure 6-20. Closing plate.
Figure 6-17. Molar strap.
Figure 6-18. Temporary locking pins (temp pins).
Temporary locking pins (temp pins)—used to secure the
pack in the temporarily closed condition prior to inserting
the ripcord pins. All pins should have long, brightly-colored
flags attached for recognition. [Figure 6-18]
Velcro® line protectors—used to cover the hook Velcro® on
the line stow pocket of reserve free bags during the line stow
process. They are made from pieces of 1" loop Velcro® with
Type-3 tape flags attached. [Figure 6-19]
Closing plate—used for closing one-pin containers. Made
from 1⁄4" aluminum with a “V” shaped notch for pulling the
closing loop up through the pack flaps while compressing
the container. [Figures 6-20]
T-bar positive leverage device—used to produce a “cranking”
action to wind up the pull-up cord, thereby increasing
leverage when closing the container. It must be used
carefully as it is possible that too much force can be applied,
damaging the container or creating too much force on the
pin. [Figure 6-21 A and B]
T-handle bodkin—used primarily for closing container systems
that have external pilot chutes, such as the Jump Shack Racer.
A minimum of two is needed for the tool kit. [Figure 6-22]
Pilot chute threading tool—used for threading the pull-up
cord through a one-pin pilot chute. A .22 caliber gun-cleaning
rod works well. The best is a United States military surplus
M-16 cleaning rod. It is made from steel, as opposed to
aluminum, and breaks down into sections and a package that
is 8" long. [Figure 6-23]
Pilot chute locking rod and strap-locking rod and strap used to
compress pilot chutes and used to hold the reserve pilot chute,
such as an MA-1 compressed on the pilot chute launching
disc. It is a tempered steel rod approximately 18" × 3⁄16".
[Figure 6-24]
Figure 6-22. T-handle bodkin.
Figure 6-23. Pilot chute threading tool. Figure 6-25. Line separator (suspension line holder).
Figure 6-24. Pilot chute rod and strap.
Figure 6-21. (A) T-bar positive leverage device and (B) positive leverage closing device with plate.
Line separator (suspension line holder)—used to keep the
suspension lines of the canopy in order while pleating. It
is made from aluminum with three “fingers” and two slots.
[Figure 6-25]
Connector link separator tool—used to separate military style
connector links, such as MS-22002 and MS-70118. The tool
is Mil Spec PN 11-1-176. [Figure 6-26]
Shot bags—used to hold the canopy and suspension lines in
place while folding. Packing weight made from nylon fabric
and filled with lead shot for weight. These should be brightly
colored or have a flag attached to prevent leaving in the
parachute. Weight varies from 2–5 pounds according to needs.
A minimum of four is needed. Making shot bags provides an
excellent sewing project for the rigger candidate. [Figure 6-27]
Seal press—used for compressing lead seals when sealing the
parachute under Title 14 of the Code of Federal Regulations
14 (CFR) part 65, section 65.133. The die of the press has
the rigger’s seal symbol engraved in the face for identifying
the seal. [Figure 6-28]
Figure 6-26. Connector link separator tool.
Figure 6-29. Lead seals and seal thread.
Figure 6-30. Rigger’s logbook.
Figure 6-27. Shot bags.
Figure 6-28. Seal press.
Lead seals and seal thread— used with the seal press to seal
the parachute, usually 3⁄8" diameter. The thread is used to seal
the parachute in accordance with 14 CFR part 65, section
65.133. A cotton thread, usually ticket 20/4 with a tensile
strength of 4.7 pounds; also used as safety tie where required.
Due to the fact that seal thread is only available in 100-pound
lots, some manufacturers buy it and then put it up on smaller
spools and make it available to riggers. [Figure 6-29]
Rigger’s logbook—used by riggers to meet the recordkeeping
requirements of 14 CFR part 65, section 65.131. [Figure 6-30]
Packing data card—used to fulfill the recordkeeping
requirements of 14 CFR part 65, section 65.131(c) that is
normally made of Ty-Vek ® material and is kept with the
parachute. Ty-Vek® is difficult to write on with a ball point
pen. One pen that works very well is the “Pilot ultra-fine
point NO XYLENE - permanent type SCA-UF.” This pen can
be found at office supply stores, although you may have to
order them. They come in black, red, and blue. [Figure 6-31]
Note pad—used for recording miscellaneous information or
making sketches when working on parachutes. [Figure 6-32]
Rubber bands—used for stowing suspension lines, bridles,
or static lines. Three sizes are common today. Besides the
normal 2-inch size, there is a smaller 1-inch size for the
newer microline and a larger one used for tandem parachutes.
Tube Stoes® used in place of rubber bands are required by
some manufacturers, such as Butler Parachute Systems, Inc.
[Figure 6-33]
Figure 6-31. Packing data cards.
Figure 6-32. Note pad.
Figure 6-34. Hand tacking needles.
Figure 6-35. Straight and T pins.
Figure 6-33. Rubber bands with Tube Stoes®.
Hand tacking needles—variety of sizes of straight and curved
needles used for general sewing are necessary for every tool
kit. [Figure 6-34]
Straight and T pins—used when doing canopy patches to
pin the fabric together. The T pins are used for heavier duty
work, such as container repair. [Figure 6-35]
Navy end tab—used for assisting in hand tacking thick
materials. This is a container end tab from a United States
Navy seat pack modified with a “dimple.” The dimple
allows the needle to be pushed through the material, and the
holes in the tab allow gripping the needle to pull it through.
[Figure 6-36]
Waxed nylon “supertack”—used for hand tacking
requirements because it has superior knot holding properties.
It is a waxed, flat, braided nylon cord that serves as a modern
replacement for 6-cord nylon. Typically 80 – 90 pounds
tensile strength, a 50-pound version is also available. This
cord is available in black and white. [Figure 6-37]
Figure 6-36. Navy end tab.
Figure 6-38. 3-cord cotton thread–waxed.
Figure 6-39. Tape measure.
Figure 6-37. Waxed nylon “supertack.”
3-cord cotton thread–waxed—used for hand tacking and
break tacking on the risers and connector links of emergency
parachutes. Its tensile strength is 16 pounds. The color is
usually natural. [Figure 6-38]
Tape measure—used for general measurement of items
such as suspension lines and bridles. A good quality tape
measure at least 25 feet long is necessary. A quality fabric
tape measure is also necessary. If possible, get one with dual
measurements (English/metric). [Figure 6-39]
Shoulder strap hook—packing assist device used to apply
tension to the pull-up cord using upper-body strength thereby
freeing both hands to pin the container. This strap can be built
by the rigger. [Figure 6-40]
Pony clamps—used for clamping material to hold it as a third
hand. Also used as a packing assistant when packing square
reserves. These do come in handy, although not used by all
riggers. [Figure 6-41]
6-inch adjustable wrench—used for tightening Rapide® links
and other jobs. A good adjustable wrench serves in place of
Figure 6-40. Shoulder strap hook.
Figure 6-43. Screwdriver–multi-tip.
Figure 6-44. Needle-nose pliers.
Figure 6-45. Cable cutters.
Figure 6-41. Pony clamps.
Figure 6-42. 6-inch adjustable wrench.
several different sized wrenches. A 4-inch adjustable wrench
is very handy as it takes up less room in the rigger kit bag.
[Figure 6-42]
Screwdriver–multi-tip—used for L-bar connector links and
general use. A good quality screwdriver with interchangeable
tips is the most versatile model. Good quality cannot be
stressed enough. If the tip of the screwdriver does not fit the
slot in the screw of a L-bar connector properly, it can slip
out and can cause damage to the screw head or injury to the
rigger. [Figure 6-43]
Needle-nose pliers—used for heavy-duty gripping and
pulling, such as for needles in webbing. A small needle-nose
plier is also handy for pulling thread after a seam ripper has
been used. [Figure 6-44]
Cable cutters—used for cutting stainless steel cable and
trimming the 3-ring release cable to length. A good quality
cable cutter, such as the Felco ™ model C7, cuts the cable
cleanly. Electrician’s pliers or diagonal cutters flatten the
ends of the wire unless they are of high quality and sharp.
[Figure 6-45]
Ripstop roller—used for applying ripstop tape for canopy
repairs. It removes air bubbles and wrinkles. A standard
wallpaper roller works well. [Figure 6-46]
Figure 6-46. Ripstop roller.
Figure 6-47. Beeswax.
Figure 6-49. (A) Hot knife element with cutting tip, basting tip, and stand and (B) heavy duty hot knife.
Figure 6-48. Spring scale and fabric testing clamps.
Beeswax—used for waxing 6-cord nylon or any regular
thread for hand tacking. [Figure 6-47]
Spring scale and fabric testing clamps—used for measuring
the ripcord pull force on reserve and emergency parachutes.
With a minimum rating of 50 pounds, it is also used in
conjunction with the fabric testing clamps to measure fabric
strength on reserve canopies in accordance with Parachute
Industry Association (PIA) TS-108. Some riggers do not use
testing clamps as they can cause damage to good fabric, if
not used properly. [Figure 6-48]
Hot knife element with cutting tip, basting tip, and stand—
used for cutting and searing synthetic materials, such as
nylon, Dacron®, and Spectra ®. The basting tip is used for
fusing canopy material in place prior to sewing during canopy
repairs. The stand is necessary to keep the hot elements from
causing a fire. A heavy-duty hot knife, although expensive,
is a must have for any serious rigger. [Figure 6-49 A and B]
Hot glue gun—used to replace staples and hand basting in
harness work. This modern tool has changed harness repair
and construction techniques. [Figure 6-50]
Tension board assembly with apex tiedown—used on the
round packing table to apply tension to the canopy when
packing. There are two models available. One is for military
style L-bar connector links and another, smaller one for
Rapide® style connector links. The straps should have a
quick release feature to release tension easily. [Figure 6-51]
Size “O” rolled rim spur grommet handset—used for doing
container repairs. The “O” stainless steel model from
Figure 6-50. Hot glue gun.
Figure 6-51. Tension board assembly with apex tiedown.
Figure 6-52. Size “O” rolled rim spur grommet handset.
Figure 6-53. Hole punches.
Figure 6-54. Cutting pad.
Stimpson Co., Inc. is the most useful grommet set because it
has a replaceable die insert section, that wears out in time and
can be replaced. It is also the highest quality. The stainless
steel set works for both brass and stainless steel grommets.
For the rigger who does not replace as many stainless
grommets, the hand set from Lord and Hodge size “0” will
also set stainless steel spur grommets, but does not last as long
as the commercial handset. The other sizes most often used
are “3” and “5” to set brass or nickel plated. [Figure 6-52]
Hole punches—used for punching holes for grommets that
come in various-sizes. Most often sizes used would be 0, 3,
and 5. [Figure 6-53]
Cutting pad—used with hole punches. The best are plastic
as these do not damage the punch. [Figure 6-54]
Rawhide mallet—used when punching holes and using
grommet handsets. This is a preferred tool to use as the
rawhide does not damage the other tools, and the weight
makes the job easier and more consistent. The number 2 size
at 4 pounds is the most common. A quality rubber dead blow
hammer works well also. [Figure 6-55]
Binding tool—used for turning corners when binding
material, such as para-pak or Cordura ®. The model shown
in Figure 6-56 is a soldering tool from an electronics repair
Figure 6-55. Rawhide mallet.
Figure 6-56. Binding tool.
Figure 6-57. (A) link fork, (B) pull check tool, (C) tool used to maintain continuity of risers when removing main parachute from harness,
and (D) Pro Pack hook.
store. The plastic handle has been replaced with a metal one.
This is almost the perfect configuration for its use.
The above tools provide the rigger with the means to pack
and maintain most of the common parachutes in use today.
There are numerous other tools, both old and new, that
individuals may wish to acquire for specialized parachutes
shown in Figure 6-57 . In particular, there are older style
parachutes and military parachutes that cannot be packed
without specialized tools designed specifically for them. At
the same time, the profession is constantly developing new
tools to make the job easier.
Sewing Machines
After the senior rigger has put together a personal tool kit,
the next step is to acquire a selection of sewing machines in
order to do minor repairs of defects found during inspection
prior to packing. For example, if you find a small hole in the
canopy, a sewing machine is necessary to make the correct
repair. For this, a lightweight single needle machine is the
perfect beginning. As your sewing skills progress, additional
specialized machines can be added as space and finances
allow. Always remember, only those repairs allowed under
your certificate may be performed.
Figure 6-58. Mitsubishi DB-130.
Figure 6-59. Mitsubishi LT2-220.
Figure 6-60. Bernina Model 217.
When purchasing a new sewing machine, if money allows,
buy the best and newest machines affordable. Do not avoid
old machines because if they are not worn out and parts
are available, they can be a good buy. If worn out, they are
counterproductive. Buy self-lubricating machines as opposed
to ones you need to oil manually. It is preferable to get
machines with a reverse mechanism. Get an adjustable “K
leg” stand and table. This allows you to set the height of the
table to best fit your physical needs. Large people bending
over a short table for any length of time understand the need
for this feature. If the rigger is buying a new machine, it is
possible to order an oversize table top in place of the standard
20" × 48" size. This allows better control over harness and
containers so they do not overlap the table.
When buying any machine, particularly from a sewing machine
dealer, get the operator’s manual and the parts manual for the
machine. The operator’s manual tells you how to set up and
operate the machine and is indispensable when the need to
order parts arises. Manuals for older machines can be found
online, along with parts manuals. When shopping for used or
older machines, seek out reputable companies or individuals
that used the machine for business, such as retiring parachute
riggers, or upholstery shops, leather shops, etc. Whenever
possible, it is always best to try the machine before you buy it.
Experience has shown that the average rigger who wishes
to set up a loft needs three initial machines: a lightweight
single needle, such as a Singer 31-15 or Mitsubishi DB-130,
for canopy repair and lightweight maintenance; a double
needle, such as a Singer 212W140 or Mitsubishi LT2-220,
with a binder or taping attachment for binding material and
light manufacture; and a medium-duty double throw (308)
zigzag machine, such as a Bernina Model 217, for suspension
line repair and replacement. [Figures 6-58, 6-59, and 6-60]
For individuals on a tight budget or with space constraints,
a good idea is to buy a double-needle machine first. By
removing one needle and bobbin, the machine performs
excellently as a single-needle machine. Replace the needle
and bobbin, and the machine again is a double needle. This
gives the rigger two machines for the price and space of one.
A good zigzag machine also does multiple-duty. Its primary
purpose is for zigzag sewing. However, adjusting the stitch
regulator allows the rigger to do an acceptable job sewing bar
tacks. By changing the stitch length and adjusting the width
to the narrowest setting, some machines do good straight
stitching, such as the Pfaff model 138.
An excellent machine for canopy patch work is an old Singer
model 201-2 made in the 1950s. Because this machine was
made for home use, they can be often be found in good working
condition. The Singer model 201-2 is unique in that it takes up
to a size 21 needle and is all gear driven with no belts. Another
portable machine, which is very handy, is the Consew CP-
146R Mini Walking Foot. [Figure 6-61] It sews a 301 straight
or 304 zigzag stitch and sews through thicker material. Both
sewing machines are good choices for traveling to the DZ.
Any machine used in parachute rigging must be capable of
using at least a size 18 needle to handle size E (69) thread. E
thread is used in most sewing done by a senior rigger.
Figure 6-61. Consew model CP-146R Mini Walking Foot.
Figure 6-62. Juki LU-563.
Figure 6-63. Consew model 206RB.
Figure 6-64. On the left is a Singer 7-34 heavy duty harness sewing machine and on the right is a Consew 733R.
The double needle machine is preferable for binding tape
repair, although with experience a rigger can install TY-3
tape with a single needle machine making two passes. When
using this method, a tape folder must be used, and the inner
stitch must be done first.
Advancing to master rigger requires additional specialized
machines, such as a medium-duty, single needle, and
compound feed machine, like a Consew 226R or a Juki LU-
563. [Figure 6-62] The Consew 206RB is also a good choice
for those on a budget. This type of machine is used for doing
container repairs and light harness work. [Figure 6-63] The
next machine should be a heavy-duty harness machine, such
as a Singer 7-33, 7-34, or Consew 733R. [Figure 6-64] These
machines specialize in sewing 5-cord nylon or heavier thread
used in the manufacture and repair of parachute harnesses.
Lastly, a bar tack machine, such as a Pfaff 3334 or Singer
69 class, allows fast, strong, professional repairs and
is invaluable in line replacement and manufacturing.
[Figure 6-65] This selection of machines provides the
rigger with the ability to undertake virtually any repair or
modification needed on today’s parachutes. Remember, all
sewing machine manufacturers build models that fit within
the various duty types. Those models mentioned are only
representative for that category. [Figure 6-66]
Identification and Nomenclature
The purpose of the following information is not to make
you an accomplished sewing machine expert and repairman.
You should learn the basics about what makes your sewing
machines work and how to perform routine maintenance