This might be a bit much for this project, but have you considered tanning your own leather? It is a challenging process (and easier with modern chemistries), but is certainly doable.
I would really love to learn how to do this, but I don't really have the time, nor the required nearby facilities to help with this. If I had a garage I'd hunt during fall and learn on a deer. For now, though, leather must be bought!!
update: I've been sick the last few days, and that coupled with an injury has got me frustrated because I can't work out, and I need bigger pecs! However since I've started this I've lost about 10 lbs so I'm happy. Being sick, however, I spent some time this weekend working on the arm band, and experimenting with dye. The results are pretty good!
Clearly some work is yet to be done here. I've gotta finish dying up the edges, and the man who's instructing me on leatherworking has stated that after waxing the leather, adding 'antiquing' dye thats been diluted all of those edges and bright spots will be covered up. He also recommended that I pull it tight over some wood and slash at the whole affair lightly with a knife a few times to simulate combat damage. As the leather is pretty thin, I worry about marring it to destruction. I'm also slightly worried that its a bit too red ... though that only appears to be the case under incandescent light and direct sunlight. I recently purchased some more dye - this time black - and will be experimenting with adding more dark to leather before I go to dye the primary girdle. I've also attached a bit of pigskin leather to the interior, which needs to be worn down a bit, and possibly dyed itself to match the feel of the latticed part. A tshirt that has been cut into long strips attaches this to my arm rather snugly - this is but a placeholder until I purchase some more leather.
Today I also received 3 bridle strap buckles, which will serve to attach the girdle to me before the corset style lacing goes over. This should allow me a good deal of adjustability, both for comfort and good fit. Once this has all been completed and installed, I'll be ready to dye and more or less finish! I'm so excited!
I've also begun to re-carve the wedding belt, this time in 'Hard' Chavant NSP, which has proven to be more flexible than its 'medium counterpart' -- if at any point I find it too hard, a quick blast of a heatgun will get it to medium, another to soft. And its hard enough to allow for very fine details, should I want them. Unfortunately the only picture I have so far is the 1/2 completed 'medium' version and its 'hard' counterpart plug before I started carving.
I've also begun to experiment with resin a little. Nothing too crazy, as of yet. I simply started with a poured coat of 15$ resin i bought at Home Depot over the blade as a way of filling the wood and a method of getting a very very smooth coat. If the spray enamel is going to work I'll need the surface as smooth as possible. That said resin seems to be very very promising as a method of forming surface. Curing in about 2 hours I was able to sand within the day, and while the surface isn't perhaps rock solid, its still very durable. The one drawback it seems is when I blow through while sanding and go down to the wood - then it starts to flake off. However, I also found that it bonds seamlessly to the Apoxie sculpt, which means a lot less sanding for me, I'm guessing, as the thick resin might fill the cracks and crags of 80-120 grit sandpaper and leave a very smooth surface. Tonight I'll be experimenting by coating the handle/hilt end.
- - - -
Finally got everything laid out like I wanted it, so I went ahead and dyed the girdle. I'm pretty happy to see that the belts match the patches of leather pretty well. After attempting to lace up the central star shapes, I found that the holes were too small to accomodate the thickness of the lace.
So I went to home depot to pick up a grommit punch that was 1/2" thickness. It seemed too small, so I also picked up a 10' pole of 1/2" conduit pipe. I was right that it was too small, so I took the pipe, cut off about 4 inches, and used a bastard file to sharpen one end. Worked Perfectly!
I also took the time to re-lace everything together (with the exceptions of the star centers, as I need to re-punch a few holes, and dye some more lace before I can actually thread them. After that I'll be using a friend to help put the holes in the adjustable belts so that I can get a good fit on the body.
Here's where its at now:
After all that is completed, all thats left to do is apply a finish to the leather, and perhaps add a softener to it to really make it supple, and its done!
I've also halted the production of the Arakh, sadly, as Its not an integral part of the outfit. I'll finish it out later, but for now the other stuff is more important