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All the talk in older posts about "personal protection items" have kinda inspired me to also have a go at making one. Here it is. Several layers of scrap vegtan. Dyed with a local spirit dye that didn't take too well, hand stitched with a 1.0 mm thick woven brown acrylic thread, stitch spacing done with an overstitch wheel at 4.8 mm length in an edge groove. Edge beveled with a Ivan tools no 2 beveler (only one I have...) What else? Oh yes, it is filled not with lead shot. I couldn't get hold of refill shot at the gun shop, they're sold out, so I opted to use some discontinued coins that are no longer legal tender. Their original value was 2c each, and the sap contains 30 coins. Here's a picture of it's innards. Since this is an instrument that will live in my car door, I used scrap leather. My stock of usable scrap is at a serious low, so I had to make do with joining the piece that is sandwiched by skiving two suitable pieces and glueing it together before completing the construction. Additionally, to ensure that the coins don't move around too badly, they are in welted enclosure. Here's a picture of the welts loaded up and ready to be closed with a piece of upholstery leather. And here's the stitching in progress... Final thickness at the business end: 15 mm, this photo is of the "handle" side.
I've been looking at previous posts on making leather slap jack style saps. I have everything I need except flat spring steel for the handle. What can I use for spring steel that will last? One post said metal packing straps but once they bend they stay bent. Anyone have any ideas for a more resilient material?