GENERAL_SHAKO_SPECS5.pdf

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SHAKO CONSTRUCTION SPECIFICATIONS

1. GENERAL

It is important that the shakos be made by the manufacturer of the uniforms. This will insure that all the manufacturer’s quality control practices will be followed. The practices include

(but are not limited to), workmanship consistent with uniform, fabric matching, and timely delivery.

2. BODY

A. Shako body is vacuum-formed high impact styrene .135” gauge white plastic and has high rubber content to prevent cracking. Body is pliable and flexible to conform to wearer’s head, in an “oval” shape, rather than circular or round.

B. There is a separate shell size for each head size.

C. Each hat has a clear ident-a-peek pocket in the inside top with the size imprinted in ¼” letters for ease of issue. Each ident-a-peek contains a card to identify the wearer. A size sticker is also applied to the inside top.

3. COVERING

A. The fabric side covering is pulled down to the bottom edge of the shako body, then turned back 1 ½” up inside the shell. Two rows of stitching secures the side covering to the molded shell. One row is polycore poly wrap thread, lock stitched. The second row is Telex 135 poly tex thread, also lock stitched. This sewing operation extends all around the entire bottom edge of the molded shako body.

B. The two rows of stitching described in section A above, secure a total of six layers for maximum durability. These layers, from the outside to inside, are: BOTTOM SIDE

BAND, VINYL HEADLINER, SIDE COVERING, MOLDED SHAKO BODY, SIDE

COVERING TURNBACK and VINYL HEADLINER TURNBACK.

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4. HEADLINER AND SPECIAL FEATURES

A. Headliner shall be cotton backed, expanded vinyl with embossed finish. There are six scallops with metal eyelets to receive drawstring for adjustability.

B. Headliner is turned and sewn with a lockstitch in such a manner to allow for adjustability.

C. Headliner extends around the bottom edge of the plastic body, and stitched through.

This results in two layers of material (outer fabric and vinyl headliner) to secure and protect the bottom edge of the shako shell body.

D. There is a metal eyelet on each side of the hat body where the button prong passes through plastic.

E. High density polyethylene plume sockets are included and riveted to the body.

F. A metal spacer is used to affix the front chain to each side button.

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5. VISOR

A. Visor is non-breakable one-piece plastic, not laminated. It is secured to the shako body with lock-stitch safety sewing.

B. Visor color is molded through entire body of visor. The material is an engineering grade copolymer with low-temperature toughness, stain proof, fade and discoloration proof, impervious to ultraviolet light (sunlight).

6. CHINSTRAP

A. Chinstrap is ¾” pliable plastic with metal buckle and roller, and has a ½” keeper.

B. There are metal eyelets at chinstrap ends where button attaches (to prevent strap from being torn by button shank).

D. There is a ¾” nickel-plated brass chinstrap hook at the rear of the shako, attached with a metal clip.

7. BUTTONS

A. Side buttons are three-piece metal.

B. Buttons consist of prongs, base plate, and face plate. Side buttons are metal with spread prongs. Plastic buttons are not acceptable.