I have been quite busy the past few days with R&D.

The one thing that puts me off with the 25th Anniversary GI Joe line is the over-sized fugly pistol holsters.

I cannot imagine anyone running around with that and pulling out a small pistol. I would have sooner just tuck my piece in my belt and chuck it away.

After putting it on safety and ensuring that there is no round in the chamber. Safety First!

The one exception is Iron Grenadier Destro. I believe his holster is the most accurate in the line.

It actually has a shape and flap!

One other problem is that these holsters are so huge that some vintage GI Joe vehicles are too cramped because of these.

Ever seeking improvements, I am half-way through making my own Joe holsters using thinner materials. It can hold GI Joe, Marauders guns, and Bbi pistols with some adjustment but still retains the box-like shape.

It is an improvement as it is more flexible and could be squeezed easily without losing shape.

It does not even scratch the pistol’s finish.

However, I have yet to perfect making Kydex holsters at this scale. So far, I have ruined 3 Marauder pistols and 1 Bbi pistol so I have to rethink this better. 

Conclusion: ABS plastic has a lower melting point compared to some plastics.

I’ll need better and smaller materials to pull this one off.

With special thanks to yojoe.com for the reference pictures.