Uniforms & Costumes:
TOS Men's Tunic - Collar Tutorial

Installing the collar into a STAR TREK: The Original Series men's service uniform tunic is regarded by many as the "worst" part of the construction process — even more-so than the invisible zipper.

This article will examine the common issues and give a complete tutorial on the "Chase method" of creating and installing a properly-fitted TOS uniform collar, which has served the author unfailingly on his replicas.

Author's Introduction

The uniform collar's daunting reputation is partly due to the sewing skill required.

An inherent difficulty is that the collar is created to be smaller than the neck hole into which it will be installed. Unlike dress shirts and other garments that have solid collars, service tunic collars are made of stretch fabric and intended to fit snugly around the wearer's neck.

Thus, the uniform maker's tasks are to:

  1. Create a collar that is properly fitted to the wearer's neck measurement.
  2. Install the collar such that it not only forms into the classic rounded "V" shape, but is uniformly stretched all the way around the circumference of the larger neck hole. (An unevenly stretched collar may put too much tension on some portions of the uniform fabric and not enough on others, resulting in a puckered or lopsided appearance.)

Unfortunately, an unnecessary second layer of difficulty is added by the majority of patterns that contain either vague or convoluted collar instructions, making this step more of an art than a science.

Experienced tunic makers develop a "feel" for collar installation, but I insist as a proponent of process and formula that even first-time builders should be able to follow step-by-step instructions that eliminate the uncertainty factor.

My method was deduced from studying the pattern drafted by Bill Theiss for Lincoln Enterprises*, and so it may perhaps be the same as was used by the wardrobe department on The Original Series.

As a disclaimer: it is possible that other costumers over the years have realised it as well, however I have never seen my particular method described or posted elsewhere. It is unlikely that anyone working with a revised version of the pattern would glean the necessary information, for reasons explained below.

*UNLESS OTHERWISE NOTED: Starfleet.ca utilises the original pattern drafted by costume designer William Ware Theiss for Majel Barrett-Roddenberry's Lincoln Enterprises in vintage size 'Large' (40). With the application of common sense, tutorials should be adaptable to any other functional rendition of the pattern, as expounded in TOS Men's Tunic - Pattern Selection.

Determining the Neck Measurement

An accurate neck measurement is required in order to customise the collar pattern piece.

Using a tailor's tape, measure around the middle of the neck where the top of the uniform collar will sit. Pull it snugly, noting that the collar fabric will have give whereas the tape does not.

Be certain to keep the tape flush to the neck and level to the ground (do not measure on an angle).

If arriving at an odd measurement, round down to the nearest quarter-inch.

WARNING: Do not skip measuring; do not assume that your shirt collar size will be the same as your uniform collar size!

A stretch collar such as the one we are creating is intended to be the same as or slightly smaller than the wearer's neck so as to form around it snugly.

In contrast, a solid collar (such as on a dress shirt) must measure larger so as not to choke, and its sole usefulness in this process is to serve as a "sanity check".

Assuming that you have in your wardrobe properly-fitted dress shirts for the purpose of wearing with neck-ties, you can verify that the measurement you took is no larger than your shirt size. Otherwise, it is unlikely you have measured correctly.

E.G.- I wear a 15.5" dress shirt and my uniform collar measurement is 15". Experimentation has shown that using my shirt size (15.5") results in a tunic collar that is slightly loose, and anything larger is very loose.

Another consideration is that stretch fabric inevitably loses a certain amount of elasticity over time, and sometimes dramatically so, depending upon the textile. A tunic collar that is already a little loose on the first wearing is apt to look sloppy by the 10th wearing. Ripping out and replacing a collar is an utterly tedious process, and it is an unfortunate waste if a tunic becomes prematurely unwearable on account of a sagging collar — thus you should take extra care to ensure that yours initially has a good, snug fit.

N.B.- Coinciding with the recommendation to build a muslin mock-up of any tunic before cutting good uniform fabric, you should absolutely install a test collar into your mock-up, but using your actual collar fabric to see if it fits the way you intend. Even a half-metre of fabric will yield numerous collars, so there should be plenty to spare.

Original Collar Pattern Piece

Before venturing to create a custom collar pattern piece, take a moment to examine the original, which is often criticised for being "too big":

Tunic Collar Pattern Piece (LE Large)

The above trace from the LE vintage size 'Large' (40) tunic pattern creates a seventeen inch (17") collar. (Similar sizing has carried over to other patterns that are based on the original.)

That may immediately seem like a drafting error. Although it is still smaller than the tunic's neck hole, it is unlikely that anyone with a 40" chest would require a 17" collar — as has been discovered by many who attempted to simply build their tunics with the piece as supplied!

However, the word "ribbing" written on the collar piece itself indicates to me that this seemingly oversized measurement is entirely deliberate.

Black ribbing was the first of two uniform collar fabrics utilised on TOS, and was employed only on the earliest of the men's hero tunics (it was supplanted with black springweave by the end of Season 1).

Thus, the first part of our theorised answer to why the original tunic pattern ships with an "oversized" collar piece is found in remembering that Bill Theiss did not initially conceive the black collars as being flush to the actors' necks at all.

The first black ribbed tunic collars appearing on-screen in The Corbomite Maneuver[1x02] still followed an overall "turtle-neck" concept from the pilot episodes, and outside the scope of academic research might be best forgotten about.

With the notable exception of Captain Kirk's tunic (which was customised for William Shatner with an ultra-low collar that remained flush only due to the addition of a special drawstring), they generally stood up and away from the neck, as in these examples:

The Corbomite Maneuver - Collars (008) The Corbomite Maneuver - Collars (012) The Corbomite Maneuver - Collars (081)

These early black collars appear substantial – akin to the large ribbed collars on the female officers' dresses – suggesting that they may have even contained buckram or another interfacing on the interior to prevent them from sagging.

The effect was unflattering, and the men's uniform tunics were revised with the familiar fitted collars containing hook-and-eye closures over the course of the next several episodes.

Given that the overall pattern we are studying was drafted with the quintessential Season 2 bell shape and raglan sleeve (Season 1 tunics were more "box cut" and featured a Saddle Shoulder), it is valid to question why the included collar piece would not have been similarly updated to a "correct" size.

The logical answer to this query is that form-fitting collars would create the need for the wardrobe department to customise them to flatter the individual actors — as indeed they did, not only in size but in shape, with various collars throughout TOS varying in height, and having neck hole shapes ranging from the circular to the ovular.

To achieve a customised fit, it is well within reason that a "stock" or "master" collar piece would be adjusted in size by the correct amount for each performer's measurements.

This is not unlike the advice given to tunic makers today, although the instruction itself is typically haphazard, such as: "once stretched around the neck hole you will find you have way too much fabric; cut the excess off".

A professional wardrobe department would presumably use a much more accurately defined process for this alteration. The next section will explain how to use your neck measurement to customise a collar pattern piece to the correct size to begin with.

Creating a Custom Collar Piece

The instructions provided with the original LE pattern provide no guidance on resizing the collar, as reproduced here for perusal: le_pattern_instructions.gif (135 KB).

All we receive are "the collar should be cut out of black fabric elasticized" and "finally, attach collar", not initially seeming very useful.

However, patterns drafted for production costume shops assume a certain level of tailoring knowledge.

One cardinal rule that is strongly emphasised throughout the instructions above is how "VERY IMPORTANT" it is to indicate notches on all pieces of the pattern, and to sew the pieces together "always matching notches".

Taking another look at the original collar pattern piece, one thing immediately evident is that there are numerous notches:

Tunic Collar Pattern Piece (LE Large)

The bottom (vertical) notches are what provide our necessary critical information.

Yet, as of this writing, every subsequent commercial pattern that has provided an updated collar piece appears to have completely eliminated the notches, drafting it as a blank strip — even in cases where it was clearly traced from the original!

Regardless of the reason for this, revised patterns – for whatever improvements they brought to the table – succeeded in eliminating the intrinsic collar guidance that the original gave us.

The Formula

Measuring the distance between notches on all three original collar pieces (S,M,L) shows that regardless of the size, one quarter (25%) of the collar measurement is to the wearer's left of the front centre notch, and three quarters (75%) is to the wearer's right of the front centre notch, with a notch marked out at each quarter. Finally, one inch (1") of excess is added onto each end (to be folded under and tacked down), with two more notches marked.

The following example chart illustrates this in further detail (click for full size):

TOS Tunic Collar Formula

On the chart, numbers above the collar note the measurements of the original size "Large" (17") collar piece, while numbers below the collar demonstrate how one would re-locate the notches to alter it for a 16" neck*.

*N.B.- Sixteen inches (16") was selected as our example neck measurement simply because it easily divides into four.

To create a 16" collar:

  1. Divide the desired neck measurement by four, resulting in four inches (4").
  2. Mark one 4" segment (25%) to the wearer's left of the centre notch.
  3. Mark three 4" segments (75%) to the wearer's right of the centre notch.
  4. Mark an additional 1" excess segment (to be folded under) onto each end*.

*N.B.- Alternatively, just half an inch (0.5") of excess can be added onto each end, at the discretion of the tunic maker. Both 1" and 0.5" measurements were employed on various screen-used tunic collars.

The custom collar pattern piece is complete!

To summarise: regardless of whether your pattern includes notches or not, any size collar can be created from any existing collar by dividing the desired neck measurement by four, marking one segment (25%) left of centre, marking three segments (25% * 3 = 75%) right of centre, and adding 1" of excess onto each end.

Assuming that you have marked all notches ("VERY IMPORTANT!"), each will line up with a specific location on the tunic for correct installation. This automatically aligns the collar, evenly distributing its stretch and tension around the neck hole.

The Side Notches

Whereas the bottom notches are entirely useful, the side notches are generally not.

These are marked at five sixteenths (5/16") and indicate that the collar was originally intended to be attached with a minimal seam allowance rather than the standard half an inch (0.5") seam allowance.

On an academic note, this is yet another piece of evidence indicating that the included collar piece is both a "shop default" and a throwback to the ultra-high ribbed collars of early episodes, examined above.

A typical collar should be installed using the standard half an inch (0.5") seam allowance, which can be observed on multiple screen-used tunics.

In short, the original side notches can be safely ignored unless the "ultra-high" look is your intention.

Fabric Selection & Preparation

Male service tunics on TOS utilised one of two collar fabrics, both of which are commercially available:

  • Black ribbing (aka common rib knit) was employed as collar fabric in the earliest tunics.
  • Springweave, a diamond weave knit, supplanted rib knit on hero tunics* by the end of Season 1, and continued to be utilised until the end of the series.

*N.B.- A belief has been stated in various forums that rib knit continued to be used on some background tunics even into Season 3, but we have not yet seen adequate evidence to confirm it as true.

Springweave is thus the more screen-accurate fabric choice in most cases, boasting even better elasticity than rib knit and possessing a diamond-weave texture that is less "common-looking" and preferred by many aesthetically.

The following screencaps show a visible difference in texture between rib knit in Shore Leave[1x17] and springweave in Space Seed[1x24], respectively:

Rib Knit Collar (Shore Leave) Springweave Collar (Space Seed)

Unfortunately, springweave is more difficult to work with than rib knit and has significant long-term disadvantages. Its great elasticity is provided by numerous individual parallel rows of elastic on the reverse side of the fabric. Like any rubber band, these loosen with time and use — sometimes drastically. The weave itself is so loose that one can see daylight when it's stretched in front of a light source, and without the elastics, it loses all stability. The uniform maker must be aware that albeit more accurate, tunics employing springweave collars will likely meet a quicker end to their useful lifetime due to the collar sagging, which was an issue that also affected the original production.

Regardless of final selection, any collar fabric employed on a TOS tunic must possess sufficient elasticity to stretch into the neck hole, but without so aggressive a resistance that it puckers up the uniform in an unsightly manner.

Especially given the omnipresent availability of black ribbing, deviating from the fabrics named herein is not recommended and should only be undertaken with excellent cause and thorough testing.

An Alternative to Springweave!

A third collar fabric option was discovered by the author in 2013 after an extensive months-long search through the offerings of numerous vendors for a suitable modern alternative to springweave, and also remains commercially available as of this writing.

Telio Paola Pique Knit

Telio Paola Pique Knit possesses a diamond-weave surface pattern that is very similar to springweave — sufficiently so that even at short range, uniform experts have mistook it for the authentic item at a glance.

This two-layer medium-weight knit fabric derives its elasticity from a fused layer of spandex that is unlikely to deteriorate as elastics do.

Although unsuitable for a fully authentic museum-quality display replica, Paola Pique is a highly practical "best of both worlds" option that is recommended by the author for use on tunics intended for repeated wear, and will itself be the subject of a separate "mini-article" to follow.

N.B.- Additional links to collar fabric sources are provided on the Links & Resources page.

Pre-Shrinking

The necessity to pre-shrink the collar fabric cannot be over-emphasised, regardless of whether or not shrinkage is expected.

Even synthetic textiles can experience shrinkage, any fabric fresh off the bolt may contain starch or other chemicals, and black fabrics are notorious for losing dye in their first washing. The exposure to hot and cold during cleaning may also affect the initial elasticity of a stretch fabric.

Ultimately, pre-shrinking ensures that any significant changes from washing the fabric will occur before the collar is cut, rather than when the uniform is cleaned for the first time. Putting one metre through a standard wash/dry cycle and then gently steam pressing it will provide a small ready-to-use supply for multiple future projects.

Collar Cutting

Cutting is straightforward: the collar should be cut from a strip of fabric folded in half, on-grain and on the fold, such that its length (circumference) follows the direction of greatest stretch.

You may be inclined to press a crease into your fabric to assist with cutting on the fold. Generally I avoid this. If you wish to do so, press said crease out of your fabric before collar installation. Collar tops should roll over smoothly wherever they meet the neck, not be pressed into a sharp crease.

Once cut out, fold in half with the wrong sides together and finish the short edges (the two ends) by zig-zag stitching each one together with black thread.

N.B.- Do not sew along the long unfinished edge at this time; that will be kept aligned manually while installing, and finished towards the end.

Tunic Preparation

At the time of collar installation, your tunic will be nearly complete.

In my own process, installing the collar is the penultimate step to attaching the Breast Insignia. (Some leave Officer Rank Insignia to the end as well, but excluding "stock" uniforms for which the final rank and/or sleeve length are unknown, there is little justification not to lay the braid while the sleeves are flat.)

Zipper Inspection

A tutorial on the hidden zipper is beyond the scope of this article, however it should already be present and installed such that it stops either half an inch (0.5") from the top of your uniform fabric (at the base of the collar), or one quarter inch (0.25") beyond that.

In the case of the former, it is advisable to remove the metal zipper pull from the slider and replace it with a black drawstring to be tucked up behind the collar. In the case of the latter, the zipper pull itself will be pulled up behind the collar and thus hidden from view.

WARNING: In either case, your stitching of the zipper tape must not infiltrate into the half an inch (0.5") seam allowance around the neck hole, or issues will arise!

Front & Back Notches

Prepare your tunic for collar installation by adding two notches:

  • Cut a notch at the centre front of the neck hole (right at the bottom point of the 'V'). This is not only used for alignment, but facilitates a crisper point on the "V"-shaped collar by allowing the seam allowance to spread open while sewing.
  • Cut or mark a notch at the centre back of the neck hole (precisely where the fold was when you cut your back pattern piece on the fold). This notch is for alignment purposes only.

WARNING: When cutting any notches, ensure that you do not clip beyond the seam allowance — quarter inch (0.25") notches should suffice!

Collar Installation

It's time to begin pinning and sewing! However, it is a classic mistake to believe that the collar needs to be pinned "all around".

The only points at which the collar will be pinned to the neck hole are at each of the five notches, which must align to the proper points on the tunic. Any additional pinning would in fact be a detriment.

Moreover, using actual pins is optional. In the case of the author's own tunics, "pinning" is accomplished simply by holding the layers of fabric together tightly by hand at each subsequent set of notches while sewing around the neck hole — without a single physical pin having been put into the collar at any point in time!

Notch Alignments

Verify five notches on your tunic per the following diagram:

TOS Tunic Collar Notches - Tunic
  • Notches 'A' and 'D' are the front and back notches added in the previous section.
  • Notch 'C' is the seam line where the right front shoulder is sewn to the right sleeve.
  • Notches 'B' and 'E' are on either side of the "faux seam" formed by the hidden zipper. Each is half an inch (0.5") from the end of the uniform fabric, in line with the zipper teeth — not right at the end of the fabric.

Corresponding collar notch alignments are as follows:

TOS Tunic Collar Notches - Collar

Sewing Instructions

Referring to the letter codes on the diagrams above, sew the collar using a standard half an inch (0.5") seam allowance, as follows:

  1. Align notches 'A'; drop your needle and presser foot. Beginning precisely at the bottom of the "V-neck" ensures a crisp centred point, which is difficult to achieve if sewing the collar in a single pass continuously around the neck hole from one end to the other.
  2. Align notches 'B'; pin and/or hold firmly together.
  3. Grasp the fabric at notches 'B'; pull gently towards you until the collar and uniform fabric between notches 'A' and 'B' stretch out to equal size and their edges align.
  4. Ensuring the fabric remains pulled taut and that notches 'B' remain aligned at all times: sew a few stitches towards notches 'B', backstitch precisely over-top to secure, then sew from notches 'A' through notches 'B' to the end of your uniform fabric, and backstitch again to secure. (Note that with 1" of excess collar fabric, it will extend 0.5" beyond the uniform fabric, whereas if you opted for 0.5" of excess collar fabric, the end of the collar fabric will align with the end of the uniform fabric.)
  5. Return to notches 'A'; drop your needle and presser foot precisely where you began (at the bottom point of the 'V'), but with your uniform turned over to sew in the other direction.
  6. Align notches 'C'; pin and/or hold firmly together.
  7. Grasp the fabric at notches 'C'; pull gently towards you until the collar and uniform fabric between notches 'A' and 'C' stretch out to equal size and their edges align.
  8. Ensuring the fabric remains pulled taut and that notches 'C' remain aligned at all times: sew a few stitches towards notches 'C', backstitch precisely over-top to secure, then sew from notches 'A' to notches 'C'. Backstitch 2 or 3 stitches to secure*.
  9. Align notches 'D'; pin and/or hold firmly together.
  10. Grasp the fabric at notches 'D'; pull gently towards you until the collar and uniform fabric between notches 'C' and 'D' stretch out to equal size and their edges align.
  11. Ensuring the fabric remains pulled taut and that notches 'D' remain aligned at all times: sew from notches 'C' to notches 'D'. Backstitch 2 or 3 stitches to secure*.
  12. Align notches 'E'; pin and/or hold firmly together.
  13. Grasp the fabric at notches 'E'; pull gently towards you until the collar and uniform fabric between notches 'D' and 'E' stretch out to equal size and their edges align.
  14. Ensuring the fabric remains pulled taut and that notches 'E' remain aligned at all times: sew from notches 'D' through notches 'E' to the end of your uniform fabric, and backstitch again to secure. (As with notches 'B' at the other end, 1" of excess collar fabric will extend 0.5" beyond the uniform fabric, whereas if you opted for 0.5" of excess collar fabric, the end of the collar fabric will align with the end of the uniform fabric.)

*N.B.- Backstitching when arriving at notches 'C' and 'D' is a safeguard that ensures you will not need to rip more than a quarter of the stitching on your collar if something should go awry while installing it.

In a nutshell, the notches ensured that one quarter of the collar fabric was distributed to each quarter of the neck hole, while pulling the fabrics between each set of notches taut such that they equalised in length while sewing automatically created the even distribution of collar tension that was being sought!

Tacking & Finishing

Put the tunic on to check collar fit.

If you are satisfied with the size and shape, finish the collar as follows:

  1. Turn the ends of collar under by folding at notches 'B' and 'E', which also turns the half an inch (0.5") seam allowance of uniform fabric to the inside at each end.
  2. Tack each end of the collar down to itself using a needle and black thread.
  3. Hand sew hooks and eyes for collar closure. Two is the standard number (although three were observed on Captain Kirk's ultra-wide rib knit collar from early Season 1).
  4. Simultaneously finish the long raw edges of your collar and the edge of the tunic's neck hole by sewing one continuous line of zig-zag stitching through all three layers. (Despite that seam allowances of screen-used tunics were unfinished in general, this particular detail has been widely observed on the authentic items.)

Your collar is complete!

Post-Installation Tightening

If an installed collar seems slightly loose, the first and fastest fix is to turn the ends under on a slight downward angle instead of straight over. In this way, you can easily remove at least half an inch (0.5") of circumference from the top of the collar and have it escape notice.

While any questions of initial collar sizing should have been addressed in the mock-up, this tightening technique can also prove useful if your collar gradually loosens after repeated wearing; simply rip out the first set of tacking stitches, re-tack, and relocate the hooks & eyes accordingly.

Further Reading

The following pages on the Star Trek Prop, Costume & Auction Authority are recommended for close-up examination of collar construction on various screen-used TOS tunics:

Acknowledgements


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