Ethofoam

The Physics of a Close Call Adam Savage recently visited the National Park Service Museum Conservation Lab to explore a haunting piece of history: a Civil War artillery jacket belonging to John Blair Royal. This garment isn't just a uniform; it’s a physical record of the Battle of Chancellorsville. A massive hole in the sleeve marks where an artillery shell wounded Royal and claimed the life of the soldier behind him. For a hardware enthusiast, the challenge isn't just the history—it's the structural maintenance of a 150-year-old assembly of cotton and wool that is literally pulling itself apart. Custom Hardware for Textile Support Textile conservation fellow Maeve O'Shea explains that displaying such an artifact is a fight against gravity. If left unsupported, the weight of the heavy fabric would cause the sleeve to sag, widening the shell hole and destroying the very narrative the museum seeks to preserve. The solution is a masterclass in custom fabrication. Using Ethofoam—a high-density polyethylene—O'Shea carved a bespoke mannequin to match Royal’s specific, "boxy" 16-inch proportions. Modular Arm Assemblies Standard mannequins don't work for fragile antiques. O'Shea engineered a custom "vest" harness with snap-on arms. This modular approach allows the conservator to dress the sleeves independently before attaching them to the torso, minimizing the mechanical stress placed on the brittle fibers. To achieve the correct "gesture," she utilized Fosshape, a heat-activated felt that can be molded into rigid, archival-grade structural supports. Materials and Interface Management Every surface interaction matters when dealing with centennial textiles. O'Shea uses Tyvek at the joints to provide a low-friction surface, ensuring the jacket slides on without snagging. Underneath the shell hole, she layered black Lycra to provide a visual "void" that highlights the damage without exposing the white foam of the mannequin. The Tactile Ethics of Conservation One of the most surprising takeaways for any DIYer is the lack of gloves. While metal artifacts require protection from skin oils, O'Shea handles the jacket with bare, clean hands. This provides the tactile feedback necessary to feel the fabric’s tension and prevent accidental tears. It’s a pragmatic reminder that in high-stakes engineering, sometimes the most sophisticated sensor is a human fingertip.