Introduction: Han Solo Smuggler Style Belt and Buckle Tutorial for Galactic Starcruiser

By www.theseep.com
About: I am an ER doc in central California that enjoys the outdoors, has a small gadget problem and has a huge interest in sustainability and environmental policy. We are on a rapid road to the destruction of our pl…

We are working on our Galactic Starcruiser personas and costumes and one of the core components is the belt! This is a brief run-through of a buckle and belt making technique that can be done with some basic leather making tools, a jig saw, and either a wire-feed welder or drill for a bolt-through option.

https://www.youtube.com/watch?v=8HvAKt9T-Zk

Stay tuned for leather dyeing and stitching tutorials!

Parts:

Tactical buckle: https://www.amazon.com/dp/B093YZXGBH?psc=1&ref=ppx_yo2ov_dt_b_product_details

2" Leather belt blank: https://www.amazon.com/dp/B07VCMK6FS?ref=ppx_yo2ov_dt_b_product_details&th=1

Chicago screws: https://www.amazon.com/gp/product/B06XMQK4VG/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

Leather punch: https://www.amazon.com/gp/product/B073SRFX5F/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&th=1

Local hardware: 1/4" diameter short studs for welding, matching receiving nuts (basically half of a chicago screw), 1/8" thick x 3" steel bar stock. For non-welded version, you'll need two 1/4" bolts with 2 nuts each, one for under the plate and the other for the buckle.

Leather dye of your choice

Step 1:

Step 1: Cut the steel bar stock to the shape you want, make sure that the buckle can be hidden behind the plate, so don't cut off too much! You can use a jig saw with a metal blade for curved and straight cuts, or a metal bandsaw for angled/straight cuts.

Step 2: Use the jig saw to cut out the metal divider on the cobra buckle and feed your leather strap through so you can lay out your pieces.

Step 3: Lay out the buckle and the studs with the buckle and mark where you'll be welding them so the cap bolts will secure the buckle to the plate.

Step 4: Weld the studs onto the plate and grind down the excess slag. Alternatively, you can drill through the plate and use a through-bolt attachment, but you'll have two bolt heads on the outside of the buckle plate.

Step 5: Fit the leather strap through, measure and punch holes for two Chicago screws on either side, leave a tail to punch new holes if you grow or want to put the belt over larger costumes/armor.

Step 6: Take everything apart, dye your leather and finish it, then reassemble your belt and start work on your pouches/accessories!