Well, this is the end. I did the bottom insert. As predicted, the bottom was a LOT harder, due to the cutout for the gun.
To begin with, just like I did on the top I used hobby felt on the bottom to provide a cushion where the taffetta cloth bears on the edge of the cardboard cutout. I was particularly concerned about the area around the rear sight and the hammer spur, as thoses areas were worn thru on the original fabric. You can just see the dark blue felt sandwiched between the cardboard and the taffetta in this photo
I also added a few more wood blocks to support areas where the original cardboard was caving in.
I then stapled the taffetta around the edge of the cardboard, just like the original material was attached. This was tricky as you needed enough slack to allow the gun to drop into the cutout, but you needed to keep things tight enough not to wrinkle. I then put the gun in the case for about a week to let the material "stretch" and take shape. I also replaced the deteriorated elastic thread for the tools
Even with the felt backing, the rear sight is already making quite an impression into the taffetta
Anyhow, here is how it looks with baby resting inside. My quest for the correct screwdriver continues, and I have to put the rest of the tools in.
Remember, this is how the case came to me
Not too bad for a first attempt!