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The first holsters I made were fiberglass, and a complete failure at every step... the silicone soaked into the MDF causing the mold to tear when I was removing it. The fiberglass went on waaay too thick, resulting in holsters that weigh almost a pound each (yes, 2 pounds of HOLSTER hanging off of my belt!).

The second pass was done as vacuum formed plastic. I didn't take progress pictures of the build since they were just stacks of MDF with very little detail. Here are the bucks on the table ready to pull:

Very simple. The two sides get glued together using strips of plastic as the bridge, then the seams are filled using Bondo, caulking or plastic melted in acetone.



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