Captain America: TFA Belt and Holster Rig - Finally done!

Kevin Gossett

Master Member
RPF PREMIUM MEMBER
After reading through Sandman0077's thread on his holster rig build, I wanted to have something like this to display with my TFA helmet and shield. Then when he decided to offer up pre-cut leather pieces, I had to have it!

So I got a full set of pieces from him, which included:

- belt
- drop leg holster rig/leg straps
- ammo pouches (4)

Everything was pre-cut, but that was it. My first task was to make sure I knew how everything was supposed to go together!

I posed a couple of questions to Sandman0077, and he was more than willing to help me out. I assembled what I could, and then asked him about a few pieces:

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He responded with this:

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So now that everything was sorted out, I was ready to start with the build. First, I used an adjustable groover to make grooves in each piece where I would be stitching. I know this isn't screen accurate, but I don't have much experience sewing, much less leather. I wanted to have the grooves to help guide my stitching and keep it straight! With that said, I loaded up the wife's sewing machine with a leather needle and began putting some of the superficial stitching in.

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With that done, I began "dry fitting" some of the pieces

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Of course I had to throw my own 1911 in there to make sure the fit was correct! :lol

Next up I began the dye process. I used Fiebing's British Tan that I picked up at Tandy

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The toughest part (for me) was the holster, simply because I knew I would be hand-stitching it all. To make things a little easier on myself, I ran the pieces through the sewing machine (sans thread) to create evenly spaced holes, so I could get a nice, even stitch. I used a lockstitch awl to stitch everything together

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And here is where I am now

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I only have one of the pouches assembled, so I still need to finish the last three. After that, I need to do a little bit of clean up work on some of the stitching, and figure out the buckle! I'm chasing a couple leads there, so we'll see what I end up with.

Oh, and a sneak peek to how this will all be displayed... I had hdtheater whip up one of his helmet stands on his CNC. Just so happens he lives about 15 minutes from me, so I picked it up yesterday...

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It looks awesome! Can't wait to get it sealed and painted up :D
 
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Re: Captain America: TFA Belt and Holster Rig

I was the commissioner of Sandman's original belt set. I could never have put this together myself...but that's looking NICE!
 
Re: Captain America: TFA Belt and Holster Rig

Thanks guys! It really hasn't been difficult--more frustrating than anything! But I love the challenge of learning a new skillset, and working with leather is quite fun!

Nick, thanks to your excellent photos Sandman was able to get a pretty darn accurate pattern together for these pieces. Thanks for that!
 
Re: Captain America: TFA Belt and Holster Rig

i have to say, i tried sewing when making old costume last year (Aladdin - street rat version) and that was bad enough! never mind having to sew leather!so for that, i say well done! looks great too by the way!
 
Re: Captain America: TFA Belt and Holster Rig

That's great work! I wish I would've felt confident enough to tackle this, if so I would've jumped on this offer when it came up from Sandman...

Either way, I love seeing this process!
 
Re: Captain America: TFA Belt and Holster Rig

Nice progress picutres. Looking forward to seeing the finished display.
 
Re: Captain America: TFA Belt and Holster Rig

Thanks again guys!

I do have a question for anyone that can point me in the right direction. I'm looking for a WWII era M1911A1 airsoft (or resin would be fine too) to display in the holster. I've looked on the bay and other airsoft sites and haven't come up with much. Any ideas?
 
Re: Captain America: TFA Belt and Holster Rig

Making your first post count! Unfortunately it is out of stock and a bit pricey for my needs
 
Re: Captain America: TFA Belt and Holster Rig

Found a cheap-o plastic airsoft on ebay that I think will suffice...

Here's a quick update:

Finished up assembling the pouches. The straps were hand-stitched using the same lockstich awl I used on the holster

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The pouches have all been glued, but only one has been stitched all around:

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I was totally going to finish them tonight! But the needle on my awl snapped, so I need to pick up a new one before I can finish the stitching. After that, all I have left to do is make the metal hanger for the holster to attach to the drop piece
 
Re: Captain America: TFA Belt and Holster Rig - How to Display?

Got some steel rod today and bent it into shape for the belt hanger. It isn't completely screen accurate, but that's because I had already sewn the piece it slides into down. Would have been impossible to slide it in place with those complex angles!

So now that this is almost finished, I need some suggestions for displaying it. Any ideas out there?
 
Re: Captain America: TFA Belt and Holster Rig - How to Display?

This is looking like a pretty good build. :cool

I used a replica holster with an old belt riveted through the grommet in the bottom of the holster, not completley accurate, but it works for now.

I'm about to begin making the pouches for my belt, probably out of vinyl, I just need to draw up, or find some patterns.

That teardrop shaped piece of leather drops down inside the holster and acts as a sort of stopper for the 1911. It's a pain to get it in there so that it is perpendicular to the sides of the holster.

As for displaying your belt, perhaps a shelf, or some "L" or "U" shaped brackets to place the belt on, and another shelf or bracket below that for the holster would work. I'm assuming you aren't displaying the whole costume as a mannequin would do the trick. I have my belt linked to the shoulder pads, sort of as a Y-harness would be, so if I were displaying mine it would be on a mannequin.
 
Re: Captain America: TFA Belt and Holster Rig - How to Display?

Thank you for the kind words! :thumbsup

Check out Sandman0077's thread linked in the OP for a pattern for the pouches. As for the teardrop piece... :facepalm :facepalm Even after he tried to explain where it went, I still wasn't quite sure, so i left it out. I may have to unstitch and put that in :)

I'm going to have to figure out the display part... Still open to more ideas!
 
Re: Captain America: TFA Belt and Holster Rig - How to Display?

Kevin, Great job building Sandman's kit.
What size are the squares on your cutting pad to help figure out the size of the belts?
Sandman's pattern is a great help but other than the holster everything else is a mystery.
 
Re: Captain America: TFA Belt and Holster Rig - How to Display?

The mat is squared inches. I can give you measurements of anything you need, just let me know. I'm away on vacation right now, but I'll be home tomorrow night :thumbsup
 
Re: Captain America: TFA Belt and Holster Rig - How to Display?

Finally getting around to work on this a little more... At the moment, I have disassembled the drop holster/leg strap pieces to rework some of them. Some of the stitching was off, and I just wasn't happy with it... So I made some patterns of the pieces, ordered more leather, and I'll get to work on those once the leather gets here.

On another note, I also finally got around to putting Jamie's (hikz) buckle on the belt, just to see how it all looks together. The buckle was 3D modeled and printed, then cold cast using resin and aluminum powder.

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The second pic is with the flash on, so you can see how it shines! It really is a great piece, has a decent weight to it, and has the look of metal.

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The above pic shows how everything will look once it is complete. I haven't attached the buckle yet, because I still haven't decided A) the best way to attach (I've seen velcro used to attach the overlapping belt straps) and B) if I want to do anything else to the buckle (round off the edges of the face sections, weather, etc)

Lastly, I started painting up my Avengers display stand today. Here it is shellaced and primered:

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I'm using a metallic satin nickel for the main portion, and then I will paint the outer ring in a metallic oil rubbed bronze color

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Re: Captain America: TFA Belt and Holster Rig - How to Display?

To be honest everything is beyond words.
 
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