Han Solo Smuggler Style Belt and Buckle Tutorial for Galactic Starcruiser

We are working on our Galactic Starcruiser personas and costumes and one of the core components is the belt! This is a brief run-through of a buckle and belt making technique that can be done with some basic leather making tools, a jig saw, and either a wire-feed welder or drill for a bolt-through option.

https://www.youtube.com/watch?v=8HvAKt9T-Zk

Stay tuned for leather dyeing and stitching tutorials!

Parts:

Tactical buckle: https://www.amazon.com/dp/B093YZXGBH?psc=1&ref=ppx_yo2ov_dt_b_product_details

2" Leather belt blank: https://www.amazon.com/dp/B07VCMK6FS?ref=ppx_yo2ov_dt_b_product_details&th=1

Chicago screws: https://www.amazon.com/gp/product/B06XMQK4VG/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

Leather punch: https://www.amazon.com/gp/product/B073SRFX5F/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&th=1

Local hardware: 1/4" diameter short studs for welding, matching receiving nuts (basically half of a chicago screw), 1/8" thick x 3" steel bar stock. For non-welded version, you'll need two 1/4" bolts with 2 nuts each, one for under the plate and the other for the buckle.

Leather dye of your choice

Step 1: Cut the steel bar stock to the shape you want, make sure that the buckle can be hidden behind the plate, so don't cut off too much! You can use a jig saw with a metal blade for curved and straight cuts, or a metal bandsaw for angled/straight cuts.

Step 2: Use the jig saw to cut out the metal divider on the cobra buckle and feed your leather strap through so you can lay out your pieces.

Step 3: Lay out the buckle and the studs with the buckle and mark where you'll be welding them so the cap bolts will secure the buckle to the plate.

Step 4: Weld the studs onto the plate and grind down the excess slag. Alternatively, you can drill through the plate and use a through-bolt attachment, but you'll have two bolt heads on the outside of the buckle plate.

Step 5: Fit the leather strap through, measure and punch holes for two Chicago screws on either side, leave a tail to punch new holes if you grow or want to put the belt over larger costumes/armor.

Step 6: Take everything apart, dye your leather and finish it, then reassemble your belt and start work on your pouches/accessories!