[lugerholsterrepair]

Wes, I have had, on occasion, found it necessary to whittle out a wooden mockup when making a baby Luger holster for the proper fitting. It is pretty easy actually. I first drew out the body of the piece on a board and then made the barrel length what I needed and cut out in rough form the outline of the pistol with a jig saw. Then I took a dremel with a sanding drum on it and started whittiling away anything that didn't look like a Luger.

I am not sure what you are wanting to end up with as mine is a little rough but it served my purpose.

Another way to go about it is injection molding. Patrick Villiers of Berlin Germany wanted an exact replica of his baby to send to me for fitting and he injection molded his pistol.

It is an amazing item as it is exact in every way. I am not sure of the process he used but I am sure you could ask him. He is found most often these days on Jan Stills Forum. Let me know if you want to contact him about this, I may have his Email. Jerry Burney