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what type material to use for belt


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Just don;t go willy nilly, James. You don;t want to pick any material. One of the main issues that comes with the belt is its ability to support the holster AND E-11 without severe droopage. Many of the belts nowadays have a plastic insert that serves as support. You can build internal support by using certain materials that not only give structure, but make it easier to sew. The originals were made from 5 layers;  3 internal layers, denim twill on the outside and satin on the inside. You don;t necessarily HAVE to use those materials, though. "Canvas" is also known as duck cloth at most fabric stores. You will also want to pick up some interfacing. This is essentially fabric glue in sheet form. It comes in many forms by you want the iron and peel kind.  First you need to measure how long this needs to be. Measure around your armor and take into consideration about 4 inches of overlap in the back.

Cut your 5 layers of fabric. These need to be kind of exact. Your final belt should measure no wider top to bottom than 3 inches. Cut 4 strips of the interfacing to match.  Start with the inner 3 layers. Grab your iron and iron one of the interfacing strips to a layer. The adhesive melts fairly quickly so you don;t need a ton of time or a SUPER hot iron. Peel away the paper backing and lay the next layer of fabric on top and iron that. Take the third layer and iron the interfacing on that FIRST. Peel the paper off and lay this, adhesive side down, onto your other two layers and iron all three until they are attached. Stitch these three layers together on the sewing machine. 

NOTE: This adhesive is just made to help you hold the material from slipping and gives a little body to the material. It's NOT a super stick adhesive like a liquid glue.

Iron a strip of interfacing to each of the last two layers. Iron those to each side of the 3 inner layers and stitch together. Add 4 inches of velcro and you're done. You don;t need any fancy binding stitching. The duck cloth WILL fray slightly. That's OK. It was like that in the film. But you can mix some White glue with a bit of water and paint it on the edge to minimize this.

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Also, others have put a plastic sheet on the left side of the belt to help prevent holster sag..., folding it in to the layers.

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