Doc FritzI have a theory about this, actually. When the EGBs first started they didn't have jumpsuits of their own. Yet, by the end of the first story both Garret and Roland were wearing them. Assuming that they had to borrow the old jumpsuits, it's obvious by the color that both of the jumpsuits were Ray's. Also assuming that the RGBs only had two jumpsuits apiece, when Ray came back both of his jumpsuits were already taken. Hence, he borrowed Egon's other one.
This of course still doesn't explain how he FIT into the darn thing, but there you go. I actually thought Ray looked a little slimmer in EGB, so maybe that's a partial explaination.
Lol…that's a funny thought…not the first time somebody's been put in Egon's flight suit, even though there's no way it could fit them right.
Are you speaking of the dreaded GB2 scene?