Drysuit zipper fraying, and plastic replacement options

[Tassie_Rohan]

Folks -

The sealing tape on my brass drysuit zipper has been fraying, and is now starting to leak slightly.

Q1) I'm curious what folks do to fix and prevent this?

I've been trimming the frayed parts and then using a lighter to melt any remaining threads. This lasts for around a dozen dive (or less) until I have to do it again.

Some groups suggest using a soldering iron to melt the edge and seal it, others suggest adding Aquaseal to the edge, but keen to hear from folks who have had the same issue.

I have been minimizing zipper use but I admit to my shame that I only lube the zipper occasionally as it opens smoothly.

Bit disappointed about this - its a relatively new suit (3 years, ~150 dives). The brass zipper on my previous 15 year old drysuit outlasted the suit: the suit started falling apart at the seams before the zipper showed any issues.


Q2) In terms of replacement zippers: how are plastic zippers looking in 2025?

I've been fed all sorts of horror stories about how bad plastic zippers are (or were): but largely from when they first started to come out. How are folks finding them nowadays? I understand there's two manufacturers of plastic zippers? If so let me know if there's a preferred manufacturer.


Cheers
Rohan.

 

[happy-diver]

Thing is the fraying edges are only a jamming hazard with the sealing happening inside the teeth where the neoprene is crumbling too so if you know how to fit one the brass urethane tape outlasts the neoprene one

 

[stepfen]

The sealing tape on my brass drysuit zipper has been fraying, and is now starting to leak slightly.

Out of curiosity on which part of the zipper is this happening?
In my case, it is happening between my chest and collarbone, exactly where the zipper is under constant squeeze from the shoulder strap.
I think the only solution is to replace it with a plastic zipper.

 

[lexvil]

I’m a plastic zip fan, added a TiZip to my old suit, totally worth the cost, my next suit came with the YKK plastic and it’s been great, now if given the option I won’t do a brass zip again.

 

[grantmac]

I far prefer a good plastic zip

 

[DiveLikeAMuppet]

You can very gently burn off the fraying parts. Just the fraying bits, preferably before you get to your stage.

You need to lube your zip more frequently.

I tend to get more fraying if I keep the zip open with the suite on - e.g. walking around a dive site, unzipping between dives.

 

[Tassie_Rohan]

Out of curiosity on which part of the zipper is this happening?
In my case, it is happening between my chest and collarbone, exactly where the zipper is under constant squeeze from the shoulder strap.
I think the only solution is to replace it with a plastic zipper.

The middle section - so shoulder to waist

I tend to get more fraying if I keep the zip open with the suite on - e.g. walking around a dive site, unzipping between dives.

Thats me most dives: for every hour of diving there's another hour of pre- and post-dive chatting and socializing. I'm usually first to suit up, and last in the water,.

Thing is the fraying edges are only a jamming hazard with the sealing happening inside the teeth where the neoprene is crumbling too so if you know how to fit one the brass urethane tape outlasts the neoprene one

Thanks - the fraying has got so close to the teeth that cracks have formed between the teeth into the sealing area. Are you suggesting resealing with urethane tape?


I've also learnt to add flammable beeswax-based lubricants AFTER I burn off the threads. Don't ask how I know.

Will have to look into TiZip and YKK plastic zippers: any preference between the two?

Thanks
Rohan

 

[happy-diver]

The tape is the foundation of the zipper upon which everything else is mounted

So if you find a zipper with a urethane tape as opposed to neoprene it's flexible and lasts and lasts
You'll just have to find one and the right fixer with the right glue swathes and swathes of Aquaseal

Dry suit - Wikipedia

en.wikipedia.org

 

[mr_v]

Rohan, fraying is typical and each zipper is rated for a specific number of "pulls." Good zippers are ~300-400 pulls. Cheaper zippers... Who knows?

In your case, you got more fraying that I'd like to see, but it is not the end. Gently burn off the ends. If the ends are too loose, cut them, then burn them. Burning long ends may lead to more fire than you'd want.

Plastic zippers are ok. I know folks using them in overhead environment. TZip and other premium zippers are the way to go.

Minimize open suit wear if you want to reduce fraying.