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  1. StrumFett's Avatar
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    Feb 12, 2012, 10:28 AM - WIP Ammo pouches fully functionnal #1

    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 Click image for larger version. 

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    Click image for larger version. 

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    Last edited by StrumFett; Dec 8, 2012 at 1:23 PM.
  2. StrumFett's Avatar
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    Feb 13, 2012, 3:26 AM - Re: Ammo pouches fully functionnal #2

    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. StrumFett's Avatar
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    Feb 13, 2012, 4:13 AM - Re: Ammo pouches fully functionnal #3

    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 Click image for larger version. 

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    Last edited by StrumFett; Feb 21, 2012 at 5:18 AM.
  4. RafalFett's Avatar
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    Feb 13, 2012, 4:35 AM - Re: WIP Ammo pouches fully functionnal #4

    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. clonecollector's Avatar
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    Feb 13, 2012, 7:31 AM - Re: WIP Ammo pouches fully functionnal #5

    Thanks for sharing!
  6. StrumFett's Avatar
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    Feb 17, 2012, 2:24 PM - Re: WIP Ammo pouches fully functionnal #6

    Here all the parts for the pouches .
    Click image for larger version. 

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    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. StrumFett's Avatar
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    Feb 18, 2012, 6:46 AM - Re: WIP Ammo pouches fully functionnal #7

    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 :
    Click image for larger version. 

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    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.
    Click image for larger version. 

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    5 - I use double side tape to stick the wood pieces
    Click image for larger version. 

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    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.
    Click image for larger version. 

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    6 - Stick the differents wood shapes using the second side of the tape.
    Click image for larger version. 

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    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. StrumFett's Avatar
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    Feb 20, 2012, 6:00 AM - Re: WIP Ammo pouches fully functionnal #8

    7 - glue the font and back parts
    Click image for larger version. 

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    8 - glue the rectangular parts of the sides
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    9 - glue the last part of the sides
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    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.
    Click image for larger version. 

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    11 - after the adjustments
    Click image for larger version. 

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    Last edited by StrumFett; Feb 21, 2012 at 5:21 AM.
  9. StrumFett's Avatar
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    Feb 21, 2012, 5:00 AM - Re: WIP Ammo pouches fully functionnal #9

    12 - Apply glue like shown on the picture below :
    Click image for larger version. 

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    13 - Proceed to assembling and use tape to maintain until drying is complete
    Click image for larger version. 

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    14 - Glue the last parts
    Click image for larger version. 

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    15 - In the same time the glue is drying, you can fix little problems in the corners
    Click image for larger version. 

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    16 - Finished !
    Click image for larger version. 

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    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. RafalFett's Avatar
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    Feb 21, 2012, 6:03 AM - Re: WIP Ammo pouches fully functionnal #10

    Well done! Can't wait to see the ammo pouch with the flap added.
  11. StrumFett's Avatar
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    Feb 21, 2012, 5:17 PM - Re: WIP Ammo pouches fully functionnal #11

    thanks for your nice comments Rafalfett !
  12. StrumFett's Avatar
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    Feb 22, 2012, 3:11 PM - Re: WIP Ammo pouches fully functionnal #12

    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)
    Click image for larger version. 

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    2 - Use double side adhesive tape to stick the metal part on the cardboard
    Click image for larger version. 

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    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)
    Click image for larger version. 

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    4 - Glue the magnet (caution : you must stick it on the other extremity)
    Click image for larger version. 

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    5 - Use glue to stick each half of the leather part
    Click image for larger version. 

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    6 - I stick the end of the flap apart because of the magnet
    Click image for larger version. 

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    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)
    Click image for larger version. 

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    Last edited by StrumFett; Feb 22, 2012 at 4:54 PM.
  13. RafalFett's Avatar
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    Feb 23, 2012, 1:08 AM - Re: WIP Ammo pouches fully functionnal #13

    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:

    Click image for larger version. 

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    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. StrumFett's Avatar
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    Feb 23, 2012, 8:30 AM - Re: WIP Ammo pouches fully functionnal #14

    Thank you very much RafalFett.
    I will make the modifications asap (today if it's possible) and post new pics.
  15. clonecollector's Avatar
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    Feb 23, 2012, 10:39 AM - Re: WIP Ammo pouches fully functionnal #15

    Really great work!
  16. StrumFett's Avatar
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    Feb 23, 2012, 3:44 PM - Re: WIP Ammo pouches fully functionnal #16

    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.
    Click image for larger version. 

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    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. RafalFett's Avatar
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    Feb 24, 2012, 1:07 AM - Re: WIP Ammo pouches fully functionnal #17

    Quote 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. StrumFett's Avatar
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    Feb 24, 2012, 4:26 AM - Re: WIP Ammo pouches fully functionnal #18

    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. RafalFett's Avatar
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    Feb 24, 2012, 7:44 AM - Re: WIP Ammo pouches fully functionnal #19

    Quote 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:

    Click image for larger version. 

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  20. StrumFett's Avatar
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    Feb 25, 2012, 1:01 PM - Re: WIP Ammo pouches fully functionnal #20

    Here is the height of the pouch :
    Click image for larger version. 

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    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)
    Click image for larger version. 

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    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. RafalFett's Avatar
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    Feb 26, 2012, 3:37 AM - Re: WIP Ammo pouches fully functionnal #21

    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:

    Click image for larger version. 

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

    Click image for larger version. 

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  22. KaanE is offline KaanE
    Feb 26, 2012, 4:17 AM - Re: WIP Ammo pouches fully functionnal #22

    Rafal, you took your measures using batninja's belt as reference?
  23. RafalFett's Avatar
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    Feb 26, 2012, 4:26 AM - Re: WIP Ammo pouches fully functionnal #23

    Quote 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. StrumFett's Avatar
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    Feb 26, 2012, 5:06 AM - Re: WIP Ammo pouches fully functionnal #24

    For the dimensions, i use tk409's template
    Click image for larger version. 

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    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.
    Click image for larger version. 

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    I sewed the flap on to the pouch at the top and bottom
    And here's the result
    Click image for larger version. 

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    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. StrumFett's Avatar
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    Feb 27, 2012, 12:28 PM - Re: WIP Ammo pouches fully functionnal #25

    I see in the gallery that the "sharped" version of the flap may be useful for an esb promotional costume
    Click image for larger version. 

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