The Dave Clark G2C was the prototype IVA space suit for project Gemini. None were flown. The flight versions were G4C and G5C.
The current concept of the pressure suit as a single-wall pressure vessel was to be retained; the basic suit could be modified by such additions as loose thermal covering or gloves and boots. To attach the astronaut to the spacecraft during extravehicular operations, a tether long enough to allow access to the spacecraft adapter section would be used; it would include 12 nylon-encapsulated communications wires. The tether's only purpose was to attach the astronaut to the spacecraft; maneuvering and maintaining stability would be accomplished by other means. Provisions for extravehicular operations were to be provided from spacecraft No. 4 on. One-half hour of useful time outside the cabin was specified as the basis for systems design.
The definitive contract for Gemini space suit was signed with the David Clark Company. Negotiations had been completed May 28. The estimated cost was $788,594.80, with fixed fee of $41,000 for a total cost-plus-fixed-fee contract of $829,594.80.
During evaluation of the G2C Gemini pressure suit in the engineering mock-up of the Gemini spacecraft at McDonnell, the suit torso was found to have been stretched out of shape, making it an unsatisfactory fit. David Clark Company had delivered the suit to McDonnell earlier in July. Evaluation in the mock-up also revealed that the helmet visor guard, by increasing the height of the helmet, compounded the problem of interference between the helmet and the spacecraft hatch. After preliminary evaluation, McDonnell returned the suit to David Clark with instructions to modify the helmet design to eliminate the fixed visor guard and to correct the torso fit problem. Final evaluation and start of production was delayed for about 6 weeks while the prototype suit was being reworked.
In general, the suit was found to be acceptable to the crew and compatible with the spacecraft. The helmet design had been corrected satisfactorily and no new design problems were encountered. Eleven G2C suits, including five astronaut suits, would be delivered by the end of February 1964. The remaining 23 suits were scheduled for a March 1964 delivery date, when qualification and reliability testing would begin. The qualification program would be managed by the Crew Systems Division of Manned Spacecraft Center.
Several components needed approval before being incorporated into the G3C flight suit configuration; CSD completed a statement of work for procuring the flight suits January 17; G3C suit procurement was expected to begin in March. Qualification and reliability tests of the G2C suit were also expected to begin in March.
Crew Systems Division began qualification and reliability testing of the suit during April.