Lizard, I am new to Leatherworker.net, but I have been working with leather for years! Holsters have always been my favorite. I too still hand stitch and have been through a lot of trial and error. I often wet form my holster with the weapon intended to be carried in it. Heavy oil and Saran Wrap keep the weapon in perfect condition. I choose a piece of leather big enough to complete the project and then wet my leather thoroughly, I begin forming it around the gun. Once I have formed the leather like I like it, I will begin to trim away excess leather around the top to begin to give the holster the look that I am after. Now I take my overstitch wheel and roll out my stitching line around the gun as close to it as possible, making sure I am on a flat plane all the way around. I then take small stainless nails or tacks and drive them through the leather at strategic points around the project into a piece of wood backing. The key here is to drive the tack in one of the overstitch marks! Gently remove the gun and touch up any forming that my have been affected and then Let it dry. Before it is completely dry I go over the stitching line with my stitching groover. The marks are still present from the overstitch wheel. I then punch each hole individually with a single diamond shaped chisel. Most times I run the stitching groover on the back side as well. I then moisten the stitching line and run the overtstitch wheel over it again to make good impressions for the stitch to lay in. The only time I have drilled holes is when I add numerous layers of leather to create what I call a welt. I will do this on the back side of the holster to accomodate thick barrels, cylinders, and semi-autos along the stitching line. You will get your "gopher mounds" at this point as well. That is how my process goes, slow, tedious, but comes out looking like a machine did it. Good luck and hope my .02 cents helps.
