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Resizing a Klassen weighted vest for significant weight changes

12 years old. Gear and prices may have changed since.

What the thread found

  • A Klassen vest can accommodate approximately 15-20 pounds of weight variation before fit changes noticeably.
  • For weight loss exceeding 20 pounds, the vest sides can be cut down and re-wrapped, with hinge holes re-drilled if needed, then reassembled.
  • Weight gain after significant loss cannot be reversed by the same resizing process, as material has been removed.
  • A hinge spacer can be added to accommodate moderate weight gain of around 15 pounds after the vest has been initially fitted.
  • The carbon fiber frame and arm components do not typically require customization during resizing, allowing the same frame to be used with modified padding and wrapping.

Depends on

  • The advice is based on experience with a specific vest model (Klassen Dual Mount, Low profile Arm, Hinged on one side).
  • The maximum acceptable weight variation and resizing limits were not definitively established by the vest manufacturer in this discussion.
  • The feasibility of cutting and resizing may depend on the hinge style (hinged on one side versus clips on both sides).
  • This represents a single user's experience rather than comprehensive testing across different body types and vest configurations.
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