Pair of Slim Jims for 1860s

[Steve75]

Thanks plinkercases.  I figure on doing one more practice run before I try it on a holster.  

[plinkercases]

if you put the stitch line a little closer to the edges you get a little more room for them on the plug.

[Steve75]

Thanks, plinkercases.  I appreciate the advise.  I have my stitch line at the muzzle of the holster and the toe plug at 3/16".  It seems like many of the pictures in Packing Iron show the stitch line is closer then what I am using.  I can try setting my stitch line for the muzzle of the holster and toe plug at 1/8".  I don't think it would be safe to go any closer to the edge.

I just completed a second trial run.  It was much easier this time.  I had an easier time getting the angle right on the awl.  I will have to revise my pattern as it will likely be to tight around the muzzle based on my two trials.  

Edited August 19, 2016 by Steve75

[plinkercases]

Looking forward to the results and shared lessons learned.

[Craig44]

 

Personally I like the Slim Jim/California style with the sewn in plug.

Second choice is squared but open then round sewn.

Why not try the sewn plug?

My preferences mimic yours.

Here's how I do a sewn toe plug, learning from Ghormley. I also set my stitch groove about 3/16" from the edge (on the holster). I pre-punch the holes in the toe at the same 7 stitches per inch spacing, before gluing/stitching the mainseam but I do it at a 45° angle. I make my plugs out of doubled 8-9oz with the flesh sides glued together. I make them a rough shape and then final shape them on the belt sander. Then cut my stitch groove closer to the edge than the rest of my work. I then glue the plug into the toe. I then carefully punch my holes with a smaller awl because the holes will be closer together than the outside. I still stitch with the same thread but use a smaller needle. I sometimes even work it out so that I stitch the mainseam and the toe plug with one continuous thread. I come around the toe and then backstitch four stitches up the mainseam.

Edited August 24, 2016 by Craig44
Typos

[plinkercases]

Nice job and good tips. I also continue around from the main seam. Goo trick to predo the holes on the body and use them as a guide for the plug holes with a smaller awl. clever.

[Craig44]

If you don't have a smaller awl, you can always penetrate the plug with "just the tip" of your regular awl. Rather than pushing it all the way through.