I've been trying to keep this part of the project a secret until I was further along, but I suppose I might as well show some progress pics!
As some of you know, I've made vinyl ammo belts in the past:
I've also created a tutorial on how to make your own:
After a few tweaks on the design (stitch width and flap corner sizing), I've decided to make Jeremy Bulloch's belt using the same process, but in leather. The base blocks are Balsa wood, covered in folded 1-1.5oz leather, with hand-stitched lacing.
I started with dying the leather, and applying a light coat of finishing wax:
I cut out the flaps and pouch covers:
The pouch coverings are wet, and stretched over the Balsa blocks, held in place with push pins until dry (then I'll glue them to the blocks).
The flap covers are wet and then folded. This make a clean fold on the edge of the flap (like the vinly original) instead of rough burnished leather:
Here's a teaser for the stitching...I had to make adjustments to the stitching groove for future flaps, so this is just a test/prototype:
Why hand-stitched? I feel I am able to keep the the stitch length more consistent with a 4-prong punch, as opposed to the industrial machines. More on that later...
The belt will be constructed the same way as the flap covers, except that I will use an industrial leather stitcher to add the lacing.
Some people have already asked if I plan to mass-produce these after the Bulloch project is completed. I may do so, however, the price increase over my former vinyl version will be considerable.