So I’ve been toying with the idea of a new holster for my DL-44 heavy blaster.  The current holster I have works great when I’m not wearing my kit.  In kit it knocks against my left knee armour because it is so long.

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I looked up Han Solo’s holster and based my ideas off his.  I started by ordering off Amazon; belt buckles, a raw 2″ leather holster belt, chicago screws, and a 12″x24″ 10-11oz piece of leather.  Then I went to a local salvage yard and picked up some old seat belt buckles (see below).  I found a place that sold Han Solo holster hardware, but it was around $100 for just the hardware.  I picked up everything on Amazon for about $100 including the leather.  I got 14 buckles from the salvage yard for $20 and only used 2 so far.  I’m planning to make my wife a dual holster for her kit and will need 4 seat belt buckles for that.

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Starting out I looked at several pictures of the DL-44 holster templates and then free-handed cut out my leather.  I used my modified DL-44 as a guide to make it fit correctly (as seen above) using Chicago Screws (3/8 in. Aluminum Screw Posts).  I had to add an extra layer of leather for these screws to be tight.

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I then used a wet mold to my leather to fit my blaster and let it dry in place overnight.  Then I used a stain; Eco-Flo 2605-03 Acorn Brown found at Hobby Lobby to stain my holster.  Holding this holster in place it is high enough to not knock at my knee plates.

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The next step I made was adding bolts from Ace Hardware to my belt buckles with JB Weld.  You can see the idea I had with the seat belt buckles attaching behind the belt buckle.  My buckle will attach in the front like a typical belt, instead of unlatching it on on Han Solo’s hardware.

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Above is sort of how it would come together; I ended up cutting the belt a little shorter to avoid the extra material bowing out as seen in the images above.

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After staining the belt I tried it on.  I noticed the other day that Han Solo wears a belt in addition to his holster rig, so I wore one for comparison.  The belt buckles have additional regular buckles JB Welded to them to loop the belt through.

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The buckle on the front had some problems and now has a bolt through the front to keep the holster in place.  It works but isn’t super pretty looking.  This holster will act as a way to hold my sidearm on my Modern Kit (Karl Dha’Werda).  It is also going to be used for my custom smuggler kit for The Dark Empire (Karl Darklighter).

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