I’ve seen people mention clothing material, which is a factor, but something I didn’t see was weight. In 2020, the average man in the US weighed 200 pounds, but in 1960 he weighed just 166 pounds and being 35 pounds down goes a long way to minimizing chub rub. I couldn’t find pre-1960 data in the brief research I’ve done, but I did see that the national school lunch program was created because a significant fraction of WWII recruits were underweight. Figure people were even thinner then, and it’s not surprising they’d have less issues with chafing than modern folks do.
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