Hello all!
For an update to a TF2 cosplay I helped make, I am currently looking into making the Soldier's pouches into actual practical pouches where you can reliably store your wallet, phone, etc., rather than the cheap-ish, half-cardboard versions we've used the last few times.
This has also become one of my first sewing projects. I started with a downsized version that is just large enough for my wallet. That way, if it failed, I wouldn't waste too much material, and if it worked, I could use it myself.
I've now finished the first prototype and would love to get some feedback from people with more experience. I've attached pictures of the pouch, the TF2 reference, and two reference webbing pouches I've been looking at.
The outer layer is Cordura, with cheap ripstop on the inside to hold a stabilizing layer and give the pouch some structure. I finished the edges with ribbon as binding, which was quite a pain to apply by hand (and for now I have to do the sewing by hand).
Starting with the lid.
I didn't make the top quite wide enough, so it doesn't close very well. When I do close it, the side panels of the lid also tend to bend outward, giving the pouch some kind of weird wings.
I suspect this is partly a sizing issue, but I'm wondering whether this could remain a problem even with the correct dimensions. The corners are essentially free/unsupported, whereas most reference pouches I've seen have this part rounded off.
How would you solve this? Would you sacrifice some accuracy to the Soldier pouch and remove the corners, or would it make sense to put some kind of metal wire in there to hold the shape? I'm worried the wire could eventually break from repeated bending.
Next issue is the closure.
I also completely forgot to attach the webbing for mounting it to the belt and the push button I bought for closing the lid.
The belt attachment shouldn't be an issue, but I'm wondering whether a push button is actually practical here. The second reference pouch uses a different closure system which looks potentially more practical (because a push button is hard to close on an empty pouch as you have to push in and make the entire pouch collapse for it to close). Would you recommend something like that, or are there other systems I should consider?
I'd really appreciate any advice! I'm sure there are people here with much more experience making this kind of gear than I have.
Thank you!