Karl Derrick has personally verified every aspect of this Mal Reynolds Holster Replica-- from the dye color to the brass buckles-- ensuring a perfect match with the original screen-used holster rig. Each replica holster is meticulously crafted by Karl himself in his United Kingdom leathersmithing shop, with the holster body and belt constructed entirely from 3.5mm heavyweight, oak-tanned steer leather. The traditionally slow-tanned, full-grain leather comes from a small family tannery and is custom dyed to specifications. The two custom colors for the rig are recorded in the tannery's dye formula book as "Malhogany" for the holster and "Kind of Brown" for the belt.
The holster's graceful vintage lines draw the eye from the triple-thickness, businesslike reverse shank, past the rugged girth strap, following the heavy-duty but elegantly stitched main seam, to the traditional open muzzle. The QMx Mal holster is entirely hand stitched with traditional waxed linen thread. The small brass buckle on the girth strap used on the original rig has only recently been identified. The QMx replica uses the exact make, model, and color as was used on the screen-used prop. The edges of the leather have been finished in the traditional manner, handed down from saddlers of the Old West. Each cut leather edge is hand burnished smooth, then sealed with gum tragacanth and a specially formulated edge coat.
Like the original, the belt gives only a single nod to decorative adornment: A simple line, incised into the leather, circumnavigates the belt's hand-burnished outer edge. Twelve pairs of oval punched holes march with orderly precision toward the rounded English strap point. Over 50 inches away, the Garrison-style military buckle glints with the warmth of solid brass. This unassuming piece of foundry brass is actually a first-generation casting of the original Mal Firefly belt buckle. The original was cast and then filled, foundry-wax copies were made from the mold. The resulting waxes were then processed into brass using the traditional "lost wax" technique. The wax model was coated in a ceramic slurry. When set, the wax was melted out and the resulting hollow ceramic shell filled with molten brass.