Paul,

I've made several belts now, using your instruction for the pattern. Worked just as you said.

I've found that almost any shape that approximates the conical shape you described works well. Here are pics of two of my latest. Both weigh a little over 3 ounces and use 2" quick release buckles. I use nylon plumbing Ts on the belt to hold the bottoms of the carbon fiber pack frame.

The one you can see through is made of mesh. It is about 4" wide throughout. I didn't taper it like you did. The mesh grips me well. No slipping.

The opaque one is made from 3" webbing. It isn't exactly conical but approximates the concical shape by putting a tuck into the back center of the belt.

Both belts fit me well and are comfortable. I have found that I don't need foam on my waist belts if they fit me well. I get a lot of sweat build up under foam belts.

Thanks again for the help. You got me on the right track.