Making Indy’s Satchel

Indiana Jones' Satchel
My replica of Indiana Jones’ satchel.

Scrolling through Market Place listings on Facebook I found two old army bags that looked similar to Indiana Jones’ satchel in the films. Without further research I grabbed them both for $20 (Australian dollars), and drove across town to pick them up.

Although similar neither matched the Mark VII screen used prop, one is a Mark V and the other a Mark VI (pictured above). A Mark VI is used in one scene in Temple of Doom but both are similar enough to use for cosplay or display purposes.

I removed the original shoulder strap, and replaced it with a 25mm (one inch) leather bridle strap cut to a length of 1625mm (65 inches). Each end is secured by a Chicago screw (also known as screw or binding posts). A slide, in this case an altered buckle, is used to adjust the strap length to get the bag sitting right on the wearer’s body.

That’s it, I will probably weather the strap to match the well-worn bag and I am looking a for a more screen accurate slide. A quick but satisfying build to get me back into making stuff after a few months of procrastination.

I gifted the Mark V satchel to my Replica Prop Forum Secret Santa recipient, and the Mark VI is for my personal collection. Now what items do I need to put in it?


FG8 Tiger Moth: Paper craft Model

Procrastination is a beast to master, and this project has been hiding in a drawer for nearly four years. I bought several model kits in Tokyo but I had only completed one small kit before this week.

Miyazaki’s film, Laputa: Castle in the Sky, is a classic and this model of the Red Pirates ship captures the beauty of his art and cinematography. 

I had set everything up to film the whole build but a focus error left me with a few hours of unusable footage. So I’ll just leave at this short fly-around of the finished model.


Quarterly Maker Box curated by Adam Savage

1:48 Scale Model of Adam Savage's Cave

1:48 Scale Model of Adam Savage’s Cave

I recently received the Quarterly Maker Box 08 curated by Adam Savage (Mythbusters,, and spent a couple of hours building this 1:48 scale model of Adam’s Cave adding a few creative touches to enliven the space.

Tested reached out a few days ago for permission to use my photo in the video for the next Quarterly Maker box curated by Adam, and I am very happy to share it with you today. The first box was the best curated box I have ever received, and I am looking forward to the new one arriving next month. Check out the video.


Christmas Tree Torture Test

Maker’s Muse Christmas Tree Torture Test

Over at Maker’s Muse, Angus designed a Christmas Tree Torture Test for us to test our 3D printers. I successfully printed it on my Cetus Extended at 90% size (to fit on the bed), 0.2 layer heights in fine detail. The print took 13 hours, and I think it did an outstanding job. [Read more…]


Turning Worn out Jeans into Useful Things

A Whale and a Bag

On a recent trip to New Zealand I wore out a good quality pair jeans but most of the material remained in good condition. I looked around for ways to recycle the material  and decided to try my hand at making a stuffed toy and a bag.

I created the whale first, and really tested my amateur sewing skills. It’s not perfect but it has lots of character and my Grandson enjoys it.

The bag seemed a more straight forward sewing exercise but it also tested my skills and my wife’s patience as she guided my efforts.

What did I learn?

Even the simplest activity requires some planning effort, creating a new object out of raw materials requires a very clear plan to ensure you don’t spend as much time fixing mistakes as I did with these projects.

Turning useless object into something new and useful is a rewarding experience, and one I wish to repeat often in the future.


Awakening the Dark Side

Repilica Prop Darth Vader Lightsaber

Tickets for Star Wars: The Force Awakens went on sale yesterday, so I thought it was time to build my Darth Vader lightsaber prop replica.

The original prop is built from a MPP flash but they are rare and expensive so I substituted the similar Heiland flash as the base for this build. The T-tracks forming the grips are attached with double-sided tape after experimenting unsuccessfully with Super Glue.

A replica MPP shroud and clamp from WannaWanga and The Custom Saber Shop respectively created the basic look and feel of the original Star Wars prop. I still require a replacement bulb release to complete it to my satisfaction but it looks great sitting next to my Luke Skywalker lightsaber.

There are several companies selling good quality replica props but it is immensely more fulfilling to build one yourself like a true Jedi.

May the Force be with you always.

Darth Vader Lightsaber


Leather Belt Pouch

Leather Pouch1

My son has a set of mini-cables he carries for work and wanted a small leather pouch to carry them on his belt. So I pulled out the sewing machine and fashioned the little pouch you see in the photo.

It’s a little rough around the edges but I kind of like the rough-made aesthetic, and it fits with the pen case I made him a few months ago. Making something useful from leather scraps, a couple of clasps and thread from Colleen’s sewing drawer is very satisfying even if it looks a little rough.

By making a few simple items I have opened myself up to many more possibilities when I have a need for something. My first instinct is to make it or re-purpose something I already have into a new use. It saves us money, and it just feels good to make a thing rather than buy it.

Leather Pouch2


Making a simple lampshade.


My desk started life as an industrial sewing machine table, and bares the scars of a long working days in this guise. Local artisan, Lloyd Kellett of One Man’s Trash, turned it into a kick ass desk lit by a beautiful Edison light bulb. It creates a wonderfully warm glow for my workspace but I always felt it needed a lampshade.

When I bought a couple of 1940s vintage flash units to replicate the lightsaber props from Star Wars, I thought one of the reflectors was a perfect solution to my lampshade dilemma. I pulled it apart, cut off the stem and used the Dremel to smooth out the rough surfaces. Then I slipped it over the socket and screwed it into place. Job done.

Making something new out of old stuff does not have to be difficult, a simple job like this can take less than an hour with basic tools (hacksaw, screwdriver and a file). In the past, most people kept their things working or created the new things they needed to live a good life. Consumerism and mass production led to a rapid loss of those skills but the maker movement is starting to revive old skills and develop new ones modern technologies.

Search the Web for makers and you find a massive community building everything from stools to small houses, from massive mechanical sculptures to miniature dioramas. Makers come in all shapes and sizes but all share a passion developed by picking up some tools and building something simple. Starting with something simple allowed them to make mistakes, develop new skills and find satisfaction in making things.

As their skills grow they move on to more complex projects but it is often the simple ones that provide us the most satisfaction. It took longer to write this post than make the lampshade, yet it makes me immensely happy to see it sitting above my desk.

Anyone can do it, so what will be your first simple project?


Making a Leather Pen Case

Leather Pen Case8The gift of a new pen (Thanks Liam, Lola & Lamb) inspired me to make a pen case to hold it and the fountain pen I received as a retirement gift. Here’s how I approached this project.

A simple design.

Every project begins with a period of contemplation to sort through ideas and search for inspiration. For this project I knew I wanted a leather case, and a bag of scrap leather recently liberated from Mum’s crafting supplies (Thanks Mum) provided the raw material. All I needed was a pattern to start making it.

Leather Pen Case1

I prefer simple designs, the case must protect the pens but remain small enough to fit in my pocket. I grabbed a piece of nubuck leather, and as I thought about the design started folding it into rough shapes. I quickly honed in on a simple three fold pattern, a rectangle folded up to form a pouch for the pens with a flap to close over them.

Leather Pen Case2

Sewing the leather.

The soft nubuck leather allowed me to use my wife’s sewing machine to sew the three straight lines to form the pouches. Transitioning from two thicknesses to three where the strap is attached proved to be a little finicky. We had to lift the sewing machine foot to get the strap under but then the machine happily worked away to complete the stitching.

I tapered the flap to fit under the strap, and the build was complete in a little over an hour.

Leather Pen Case4
Be prepared to fail.

Failure is always be an option when making something, particularly when developing new skills. My maker idol, Adam Savage, is steadfast in his belief that we learn more from our failures than our successes. He encourages makers to build prototypes out of cheaper materials like paper and cardboard before tackling the final product. Even a simple project like this one can benefit from prototyping.

I planned to build a paper model first but I decided to just dive straight into the final product. As a result, I only discovered an error in my pattern after I finished the sewing. I wanted the smallest possible case for two pens but my conservative pattern was too wide, and just looked wrong in my hand.

Luckily I could correct this mistake without a complete rebuild by resewing the outer edges to give the case a slimmer profile.

I am really pleased with the final product and it feels good in my hand.

Leather Pen Case7
Making vs Buying

I looked for pen cases in the shops, and they typically cost $50-$100 for a simple leather model. While speciality stores displayed beautifully crafted items I found taking the time to make my own case a joyful experience. It gave me a sense of achievement that buying stuff can never emulate, and I started me thinking about other leather work projects.

It feels good to be a maker of things.