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WIP Ammo pouches fully functionnal

  1. #1
    StrumFett's Avatar
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    WIP Ammo pouches fully functionnal

    EDIT 12 - 8 - 2012 : Finished ! (almost)
    EDIT 11-11-2012 : Pics of finished pouches

    EDIT 05-19-2012 : Tutorial for belt assembly is finished. Files below.

    Belt assembly A4.zip
    Belt assembly LTR.zip

    EDIT 05-17-2012 : Belt measurements and templates corrected with the help of RafalFett. Tutorial for assembling the belt will follow.
    Belt measures and templates A4.zip
    Belt measures and templates LTR.zip

    EDIT 05-16-2012 : Belt templates are achieved. Working on belt structure.
    EDIT 05-07-2012 : Belt overview with measurements is achieved.

    EDIT 04 - 19 -2012 : Sewings part achieved. Begin to work on belt.
    7 - Sewings - A4.pdf
    7 - Sewings LTR.pdf

    EDIT 04-15-2012 : Flap tutorial and templates are achieved. Zip files can be downloaded from links below. The sewings are still missing and some paint is needed on visible cardboard.

    Flap templates and tutorial A4.zip
    Flap templates and tutorial LTR.zip

    EDIT 03-21-2012 : I've just finished assembling my 7 pouches. Now i'm working on the flaps. Here's the overview:

    4 - Flap overview - LTR.pdf
    4 - Flap overview - A4.pdf
    EDIT 03-04-2012 : The templates for inner part of the pouch using RafalFett dimensions are achieved :they can be downloaded in both formats A4 or US LTR:

    Pouch inner part LTR.pdf
    Pouch inner part A4.pdf


    EDIT 02-27-2012 : I make a comparative of 3 pouches dimensions i found on the site (Batninja, TK409 and Rafal).The result show that i need to make some modifications to my template to be more accurate.
    EDIT 02-26-2012 : Second part achieved
    EDIT 02-25-2012 : Flap and sewing finished. Begin how-to attach flap on pouch
    EDIT 02/22/201 : Second part of the tutorial started (see below)
    EDIT 02/21/2012 :
    The first part of the tutorial is now complete.
    The second part will concern the flap around the pouches and using magnet to maintain pouch closed.
    The third part will be about weathering and how to adjust color if you can't find the right one
    The last part will be the making of the belt

    i guys!
    It's my first contribution to this site. I begin to make an ammo belt for my costume and i have the idea to make it functionnal. I'm not the first to think it but my approach is differents than the others.
    First i want to thank tk409 for posting pattern of the pouches. I use his work to make mines.
    The pictures below show the first try with the pattern i designed.
    Give me your opinion.
    Attached Thumbnails Attached Thumbnails 8-belt-overview-jpg   4-flap-overview-a4-jpg   2-wood-structure-parts-jpg  

    1-pouch-overview-jpg   dscn6330-jpg   dscn6329-jpg  

    dscn6335-jpg   face-jpg   dos-jpg  

    dessous-jpg   cot-jpg   dscn7534-jpg  

    Last edited by StrumFett; Dec 8, 2012 at 1:23 PM.

  2. #2
    StrumFett's Avatar
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    Re: Ammo pouches fully functionnal

    EDIT : These files corresponds to an ancient version. Please use those in Post #1.
    First part of the tutorial :

    EDIT 02/21/2012 : I add a zip file with the pattern in formats wmf an adobe illustrator (the adjustments will be easier).

    This is the pattern in 3 PDF (A4 format). In this version there will be no gap in front as shown in the precedents pictures.(it's not a real problem because it will be invisible when the pouch will be finished).
    After you print the pdf and reconstitute the pattern, i recommend you glue it on cardboard to increase the strength.
    In the last pdf, you will find the pattern for the wood pieces i use for the structure.
    I use plywood of 3 or 4 millimeters of thickness. You can use also medium (i don't know if the name is the same in your country, it's wood reconstituted with particles and it's cheaper than plywood).
    In my next message, i will post a step by step tutorial with pictures.
    Attached Files Attached Files
    Last edited by StrumFett; Apr 15, 2012 at 4:14 PM.

  3. #3
    StrumFett's Avatar
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    Re: Ammo pouches fully functionnal

    The first step :
    1 - Print the wood pattern
    2 - Glue it on cardboard (i use an old playmobil box)
    3 - Cut the differents shapes
    4 - Draw the shapes on the plywood (see the second picture to optimize the material)
    5 - Cut the shapes
    Attached Thumbnails Attached Thumbnails cardboard-pattern-jpg   before-cutting-jpg   wood-pieces-jpg  

    Last edited by StrumFett; Feb 21, 2012 at 5:18 AM.

  4. #4
    RafalFett's Avatar
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    Re: WIP Ammo pouches fully functionnal

    You did a great job so far! Just keep the info and the images coming. This will be a real help for those who want to build their own ammo pouches.

  5. #5
    clonecollector's Avatar
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    Re: WIP Ammo pouches fully functionnal

    Thanks for sharing!

  6. #6
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    Re: WIP Ammo pouches fully functionnal

    Here all the parts for the pouches .
    wood-parts-finished-jpg
    Time spent : 1 hour from cutting paper shapes to job finished
    Money cost : between 2 or 5 (depends which wood you use)

    Next step : Cutting shapes in leather and assembly.

    In fact i will not use real leather (it's too expensive and hard to work).
    I found leather imitation on internet(140 cm wide) for 7 by meter.I think that 2 meters are sufficient.

  7. #7
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    Re: WIP Ammo pouches fully functionnal

    Step 2 : Cutting leather shape and assembling
    1 - Print the 3 files, assemble them and cut the shape in paper
    2 - To increase strenght, glue it on cardboard.
    3 - This is th material i will use :
    front-jpgback-jpg
    I think the color is a little too dark but i will try to correct this later.
    4 - I use tape to maintain the pattern and i cut the shape using a cutter with a new blade.
    leather-shape-jpg
    5 - I use double side tape to stick the wood pieces
    double-sided-1-jpgdouble-sided-tape-jpg
    beware of the sides pieces, i make a mistake on mines because i stick tape on the same side.
    I use a white pen to make marks on the backside of the leather shape. It's more easy to put correctly the wood pieces after.
    white-marks-jpg
    6 - Stick the differents wood shapes using the second side of the tape.
    wood-pieces-position-jpg
    I use matches to keep a space between the front, bottom and back pieces.
    Last edited by StrumFett; Feb 21, 2012 at 5:19 AM.

  8. #8
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    Re: WIP Ammo pouches fully functionnal

    7 - glue the font and back parts
    sticking1-jpg
    8 - glue the rectangular parts of the sides
    sticking2-jpg
    9 - glue the last part of the sides
    sticking3-jpg
    I use a battery to press the joint between the 2 parts.
    10 - A this step, some adjustments will be necessary. Because tickness of the materials you use may be different than me, you will need to adjust some dimensions of the pattern.
    sticking4-jpg
    11 - after the adjustments
    sticking5-jpg
    Last edited by StrumFett; Feb 21, 2012 at 5:21 AM.

  9. #9
    StrumFett's Avatar
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    Re: WIP Ammo pouches fully functionnal

    12 - Apply glue like shown on the picture below :
    applying-glue-jpg

    13 - Proceed to assembling and use tape to maintain until drying is complete
    assembly-1-jpg

    14 - Glue the last parts
    assembly-2-jpg

    15 - In the same time the glue is drying, you can fix little problems in the corners
    asembly-3-jpg

    16 - Finished !
    assembly-4-jpg

    Remember : Make the first pouch complete to make adjustments in the pattern before starting others.

    Next Part : The flap around the pouche.
    to be continued...
    Last edited by StrumFett; Feb 21, 2012 at 5:23 AM.

  10. #10
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    Re: WIP Ammo pouches fully functionnal

    Well done! Can't wait to see the ammo pouch with the flap added.

  11. #11
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    Re: WIP Ammo pouches fully functionnal

    thanks for your nice comments Rafalfett !

  12. #12
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    Re: WIP Ammo pouches fully functionnal

    SECOND PART OF THE TUTORIAL : THE FLAP

    1 - This is all the parts :
    the leather part (cut with the template i will ppost tomorrow)
    a cardboard rectangle : it adds more rigidity to the flap (i use thin cardboard so you can make the sewings with sewing machine)
    a metal plate( cut in an old pc power supply case)
    a neodymium magnet (you can find them on ebay for 3 or 4$ for 20 pcs)
    principle-flap-jpgflap1-jpg
    2 - Use double side adhesive tape to stick the metal part on the cardboard
    flap2-jpg
    3 - Use double side tape to stick the cardboard with the metal plate on the leather (you can make marks to help you center the cardboard)
    flap3-jpgflap4-jpg
    4 - Glue the magnet (caution : you must stick it on the other extremity)
    flap6-jpg
    5 - Use glue to stick each half of the leather part
    flap7-jpg
    6 - I stick the end of the flap apart because of the magnet
    flap8-jpg

    7 - Cut the angles
    The result ( the sewing are missing, color is needed at some points but you can see that the mechanism is invisible)
    flap11-jpgflap10-jpg
    Last edited by StrumFett; Feb 22, 2012 at 4:54 PM.

  13. #13
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    Re: WIP Ammo pouches fully functionnal

    The ammo pouch now looks good and it will be great after the flap will be sewed. But the problem is that the ammo pouch looks too chubby, so I did a comparison image for you:

    ammo-pouch-compare-jpg

    I know that you used existing templates for your work, but you can do the necessary adjustments to have an excellent (and working) replica.

  14. #14
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    Re: WIP Ammo pouches fully functionnal

    Thank you very much RafalFett.
    I will make the modifications asap (today if it's possible) and post new pics.

  15. #15
    clonecollector's Avatar
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    Re: WIP Ammo pouches fully functionnal

    Really great work!

  16. #16
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    Re: WIP Ammo pouches fully functionnal

    Thank you very much clonecollector!
    Here is a second version (make with the advice of RafalFett, thanks again to him). I made it quickly so the quality of work isn't very good.
    I think the shape is good.The only thing i will change perhaps is the cormers of the flap ( i think that i cut a too big part)
    If you agree with it RafalFett, i will produce the new template.
    pouch-v2-jpg

    note : i find on tk409 site a very useful link talking about differents Boba belts
    I see for example than the ESB belt has only 2 grommets while ROTJ belt has 6 grommets
    Here is the link : Fett Ammo Belt

  17. #17
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    Re: WIP Ammo pouches fully functionnal

    StrumFett said: View Post
    If you agree with it RafalFett, i will produce the new template.
    I'm in no way related to the ammo pouch templates. But you could contact the original maker of the templates, and if he agrees that you can modify and post his templates, then you are fine.

    I really like how the ammo pouch looks and I think it will be perfect after the flap will be sewed.

  18. #18
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    Re: WIP Ammo pouches fully functionnal

    I'm sorry, my comment wasn't very clear.
    I'm the author of the templates. I used tk409 one only to have the dimensions of the pouches.
    In my last post, my question was only if you think that the shape is correct with the modifications before i post a new template.
    Thank you again for your very quick response. I have finished the new template with a lot of improvments.
    I will make a last try before posting it.
    I make modification on flap template too.

  19. #19
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    Re: WIP Ammo pouches fully functionnal

    StrumFett said: View Post
    I'm sorry, my comment wasn't very clear.
    I'm the author of the templates. I used tk409 one only to have the dimensions of the pouches.
    In my last post, my question was only if you think that the shape is correct with the modifications before i post a new template.
    Thank you again for your very quick response. I have finished the new template with a lot of improvments.
    I will make a last try before posting it.
    I make modification on flap template too.
    My mistake! I don't see any measurement on your files, but my calculations says that the ammo pouch should have this hight:

    pouch-20v2-jpg

  20. #20
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    Re: WIP Ammo pouches fully functionnal

    Here is the height of the pouch :
    height-jpg

    8 - Sewing :
    Due to the fact that i haven't a sewing machine and no money to buy it i decide to make sewing by hand :
    I make a template and stick it on heavy cardboard.
    I use a dremel with an 1 mm metal drill
    I use a leather needle and make the sewing (it takes 30 min to make holes and half sewing)
    sewing1-jpgsewing2-jpgsewing3-jpgsewing4-jpg

    For this flap, i used sevaral parts of cardboard (one for each side of the pouch) with an interval of 3mm. The result is that the flap takes shape more easily.

    When i will finished this one, i will post all the templates corrected.
    Last edited by StrumFett; Feb 25, 2012 at 3:59 PM.

  21. #21
    RafalFett's Avatar
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    Re: WIP Ammo pouches fully functionnal

    The general look is very good, but I think that is better not to use cardboard in the flaps and leave the flap cornerless. Here are my measurements of the ammo pouch without the flaps:

    ammo-pouch-measurements-jpg

    Note that the ammo belt measurement is from one of batninja's templates:

    belt_template-jpg

  22. #22

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    Re: WIP Ammo pouches fully functionnal

    Rafal, you took your measures using batninja's belt as reference?

  23. #23
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    Re: WIP Ammo pouches fully functionnal

    KaanE said: View Post
    Rafal, you took your measures using batninja's belt as reference?
    I did my measurement using other factors, but when I compared my measurements to batninja's belt template, it gived me the same dimension.

  24. #24
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    Re: WIP Ammo pouches fully functionnal

    For the dimensions, i use tk409's template
    template-gif
    Some dimensions are differents (for example height of the pouch is 8,5 cm). What is the better between batninja template and tk 409 's one ?

    And the last part of assembly :
    I glue the front, bottom parts of the flap. For the back, i use a cardboard template to make holes in the flap and the pouch.
    final1-jpgfinal2-jpgfinal3-jpgfinal4-jpg
    I sewed the flap on to the pouch at the top and bottom
    And here's the result
    final-5-jpg

    I agree with RafalFett to keep the "rounded" flaps. It was just a test but result is less accurate.
    Last edited by StrumFett; Feb 27, 2012 at 12:10 PM.

  25. #25
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    Re: WIP Ammo pouches fully functionnal

    I see in the gallery that the "sharped" version of the flap may be useful for an esb promotional costume
    boba-fett-promotional-armor-2-03_1979-11_-_gold_circle_columbus_ohio_01-jpg

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