Finally it was time to make it.
I made similar adjustments to last time.
I sewed on a badge from his favourite surfing shop
I added adjustable straps using fabric, padding, webbing and ladder lock clips.
I used the last scrap of waterproof fabric from the stash to make a waterproof lining (so he can use it for swim kit)
I had to use clips to hold all of the layers together! Pelmet vilene used to stiffen the front and back (I prefer fusible volume fleece but did not have any left in the stash!)
Put in a magnetic closure for the front pocket not a velcro one (velcro just attracts grass and sand and then stops working)
Get a open ended zipper (x2) cut off the ends - thread the zipper pull from one onto the other.
Sew both ends shut
Add a fabric "stop" to the ends
And done! It took less than a day to do - cut out one evening & most construction - final construction the next morning... as usual... why did I leave it so long to do?