The Logistics of Mud: Transporting Gear in the UK

Top Tips: Packing a Drysuit for Transport

The most expensive item in your kit bag is also the most vulnerable to “crush damage.” Throwing a 3kg steel backplate on top of a plastic drysuit zipper is a £250 mistake.

Here is the professional method for folding and packing a drysuit to ensure the zip and seals survive the journey.

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1. The “Open or Closed?” Rule

This is the most common error divers make. The rule depends entirely on your zipper material.

• Metal (Brass) Zippers: Transport OPEN.
  • Why? Metal teeth are rigid. If you close the zip and then fold it, the tension on the outer rubber sealing element can cause it to crack or delaminate. Leaving it open relieves the stress.
• Plastic (YKK/TiZip) Zippers: Transport CLOSED.
  • Why? Plastic teeth rely on a tight interference fit to seal. If left open, the sealing lips are exposed to dirt, grit, and crushing. Closing it protects the sealing surfaces and keeps the teeth aligned.

2. The “Concertina” Fold (Step-by-Step)

Never just stuff a drysuit into a bag. You must control where the bends happen.

1. Lay Flat: Lay the suit face down (for back entry) or face up (for front entry) on a clean surface. The zipper should be facing UP so it is on the outside of the fold, not crushed on the inside.
2. The “Knee to Chest” Fold: Fold the boots/legs up until the knees are touching the chest area.
3. The Tuck: Fold the arms inwards across the chest. Crucial: Tuck the wrist seals inside the sleeves. This protects the latex from snagging on the zipper or bag mesh.
4. The Roll: Roll the suit loosely from the bottom (boots) up towards the neck.
   • The Result: You end up with a bundle where the zipper is curved gently on the outside, not creased flat.

3. Loading the Box: The “Heavy-Light” Hierarchy

When loading your rigid plastic box or roller bag, gravity is your enemy.

• Base Layer: Fins, Backplate, Cylinder Bands, Lead Weights. (The uncrushable heavy items).
• Middle Layer: Regulators (in a padded bag), Mask box, Accessories.
• Top Layer:The Drysuit.
  • Why? The drysuit acts as a lid. It cushions the gear below, but more importantly, nothing heavy is pressing down on the zipper.

4. Seal Defense

• Latex Seals: Before leaving the house, give them a light dusting of unscented talc. This acts as a dry lubricant, preventing the latex from sticking to itself and ripping when you unroll it at the site.
• Neoprene Seals: Ensure they are not folded flat with a sharp crease. If possible, stuff a clean sock or a small foam roller inside the neck seal to keep it round during transport.

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💡 Pro Tip: The “Zip Guard”

If you have a metal back entry zip, it is vulnerable to being crushed by the boot of your car or other boxes.

• The Hack: Buy a short length (50cm) of foam pipe insulation (lagging) from a DIY store.
• The Use: Slip it over the open zipper teeth before you fold the suit. It creates a “bumper” that prevents the teeth from being smashed if something heavy lands on your bag.