During preproduction of King of the Rocket Men, the writers had a completely different vision for the flying suit.  The original draft described it as, "a man-sized fabric suit, vaguely resembling a diver's outfit, and complete with skull-tight helmet and wide-view goggles. Material, suggesting a bat's wings, is fastened to the length of each arm and attached to the body sides, creating a webbed effect.  A broad belt encircles the waistline, from which hangs a square-shaped holster containing an odd looking weapon to be identified later as a sonic gun.  Attached to the front of the flying suit, with two straps that fit over the shoulders, is a compact jet propulsion tube and fuel tank, equipped with a small control panel whose several dials and operating buttons would be visible to the wearer."  Thank God for rewrites!

In order to allow for spontaneous quick changes in the serial, the flying suit became a more portable apparatus.  The Lydecker Brothers, Republic's special effects wizards, probably had some input on the design and fabrication of the helmet and rocket pack.  The helmet was reportedly made of aluminum with a hinged visor similar to that found on a welding helmet.  When lowered, the visor was held in place by metal clasps, the same type used on those plastic raincoats we wore as kids.  To give the suit a more self-contained look when carried, the helmet snapped over the upturned collar of the black leather jacket in three places.  Because this system would severly restrict head movement, the helmet was probably left detached when worn.  The visor fit so snugly against the actor's face that chin and nose padding was added to the inside surface for protection.  A stunt helmet, complete with screen visor, was used during many "take-off" scenes in order to improve visibility and minimize possible injury.

Tris Coffin wearing original suit	George Wallace in revised helmet

Dave Sharpe in stunt helmet with mesh visor

The rocket pack ws probably aluminum or some other lightweight metal as evidenced by the occasional dent received during fight scenes. The unit was attached with screws, two per side, to a leather back plate which was then secured to the back of the jacket in two places. The 3" wide leather belt, which secured the back plate at the waist, featured a modified B-17-style quick-release safety buckle (see Replicas page for more details).  The chest-mounted "control panel" was probably made of wood with two vintage heater control plates "ON OFF UP DOWN" and a surplus dial calibration plate "SPEED CONTROL- SLOW FAST" tack riveted to the panel assembly. Two round post knobs and a "chicken head" dial served to regulate suit functions.  The complete assembly was attached to the front of the jacket with two screws on the right side and a snap on the left, which constantly popped open during stunt fights.

The flying suit underwent minor modification in each of the other two serials, Radar Men from the Moon and Zombies of the Stratosphere.  Instead of the previous stand-alone version, the suit became an ensemble, with jacket and helmet as seperate components.  Both heroes, Commando Cody and Larry Martin,had an assistant to help them while donning the costume.  During the filming of Radar Men, George Wallace was pestered by small insects inside the helmet while on location, so a leather or foam piece was fitted to the bottom of the visor with gaffer's tape to keep out unwanted guests.  This piece became smaller in Zombies and a new gadget, a belt-mounted radio unit, allowed the intrepid Larry to communicate with his associates while in flight.  In the series Commando Cody, Sky Marshal of the Universe, Judd Holdren wore a cap and uniform as well as a Lone Ranger-style mask in order to keep his identity a secret (and allow the producers the option of replacing Holdren if necessary).