Zipper Modification for Light Gear

Outdoor Research Centrifuge JacketOne of the problems about favoring light gear, clothing included, is that every aspect of the gear is light. This includes the zippers. With light zippers comes small zipper pulls, not something I relish in winter clothing where tugging on these things often involves gloved hands. This usually leads to some low-level cursing and removal of gloves to get the job done.

A couple of frustrating tugs of the zippers on my new favorite garment, the Outdoor Research Centrifuge Jacket, and the wheels started turning for a solution. What I came up with turned out to be very elegant and simple.

My solution involves electrical shrink tubing and pieces of zip ties for structural stiffening.

Most zipper pull shapes will work although a pull with a wide section along it's length assures greater security of the modification than a straight or tapered design. I used a medium width zip tie for structural support but any piece of plastic will work. Alternatively, a piece of cord passed through the near end of the zipper pull and then covered with shrink tubing would also work but I have not experimented with this version. I was so satisfied with the pictured version I stopped there.

Shrink tubing requires the heat of a flame to shrink it down so you have to be careful with your sexy new nylon jacket as you work. I came up with a way to protect the fabric while applying the flame. Very simple and effective. Just punch a hole in a piece of thin cardboard, stick the zipper pull through it and melt away. Always good to avoid melting holes in your new $125 jacket. 

By the way, this Outdoor Research Centrifuge Jacket is the bomb. It's the perfect top for the light and fast advocate. The wind proof front sheds any weather coming at me and the fully breathable rear of the garment keeps me well-ventilated.

The light pile in the back also adds some stretchiness to it so I can where my hydration bladder under it and still get my skins stored in the front for descents. My medium weighs in at 380 grams which is pretty damn light for a jacket this versatile. Three pockets in the front allow me plenty of food storage. And now that I've done my thing with the zipper pulls, I want for nothing. - Brian