Next you need to size up your model. Han's belt sits at the hips below the belt line. I began by cutting strips of foam to piece together to make the belt. I cut 3, 2" wide strips. The first strip was sewn directly onto the front buckle. An important note about this, the attached portion of the belt to the buckle is on the right side (when you are wearing it). After the first strip was attached I added the other two strips (taking into account the fact that belts are not perfectly straight but become angled due to wear). In order to make this process more attractive I attached the strips by butting the two strip up next to each other and hot glueing a small piece of foam being them and then stitching "X"s to give it a custom look.
Now the belt has to be made the proper size so you'll need your model again. In order to keep this item cheap I used a buckle like what is found on a pair of overalls. I attached the "button holder" end to the end of the belt strip and attached a button to the back of the buckle. This belt will not be constantly taken on and off so I think it should hold up alright.