The Sleeve worked out great. CO 42, worked 10 rows 2x2 rib. Increases on the 1st and every 8th row until 72 sts, it measured about 22 1/4 inches long. armhole shaping cast off 4 sts at begining of next 2 rows, 3sts on next 2 rows, then decreased at each end every 3rd row 11 times [36sts].
Cast off 3 sts at beg of next 6 rows. Cast off remaining 18 sts.
Just to make sure I quickly stitched it all together and had himself try it on and it is a good fit, so the second sleeve is on the way up and at some point I have to go hunting for a very long zipper, but that'll be when everything is knitted and sewn, as I want to have the right length.