A method of assembling a surgically implantable fluid adjustable device. The device has an elongated substantially air impermeable flexible inflatable portion, an elongated flexible and substantially inextensible band portion attached to the inflatable portion, and a catheter tube in fluid communication with the inflatable portion. The catheter tube has a distal end attached to the inflatable portion and an open proximal end extending therefrom. The method involves substantially evacuating the inflatable portion of fluids, and inserting a removable plug into the open proximal end of the catheter tube such that it substantially prevents introduction of air through the proximal end.