NZcaver wrote:I'm not sure about you, but most of my harnesses are made from about 50mm (2 inch) webbing. I rig with 25mm (1 inch) tubular webbing, but I wouldn't want to use it too often as a harness. Ouch!
Not to knock knotted harnesses (try saying that fast!), but those knots can be bulky and painful - especially in larger webbing.
We predominately use 2" webbing for rigging (although there is some argument) I personally prefer 1" tube tape as it's easier to handle etc. Tube tape and 2" flat are basicly the same thing as far as strength goes AFAIK.
I think I have made abseiling harnesses out of 1" tube tape when I was younger if I remember rightly they weren't too bad.
I agree a knotted harness is unlikely to be very comfortable but at least it is a known quantity and safe - I know what I'd prefer. (my opinion only of course)
You guys in the US have better access to different harnesses anyway and they are cheaper too, here it's either Petzl caving harnesses or nothing and it was a reasonable amount cheaper for me to order from the US and pay frieght than get one locally (and the local one was already pretty heavily discounted) given that, I'd just buy a new harness (but I've already said that)
PS: Harness Hang Syndrome is a safety aspect we haven't brought in to this discussion
Is a bought or more comfortable harness more likely to protect you from this danger?
More about HHS here:
http://www.texasroperescue.com/library/Harness%20Hang%20Syndrome.htm