I've got a couple of Gallery Mint concept dollars that are exactly the diameter of a Sacajawea dollar, but twice as thick. I'd like to put them in a holder that's more protective than a plastic flip, but I can't find one! Do I have no other choice than to get them slabbed if I want a little more protection for these cool pieces?
Good point. My guess is that a pair of ANACS slabs would come out to less than a custom Capital holder.
Custom manufacturing isn't cheap. And there's probably, I would guess, a minimum number you would have to buy.
Check the Air-Tire website. They may have something so long as you have calipers to take measurements. You may want to email the Capital and Air-Tite because they may have something that's not on their website.
I have this coin in a lighthouse 2x2 cardboard flip. It is about 3 times the thickness of a quarter at it's highest point (these ancient coins were very high relief). Lighthoue flips have very soft mylar that will contour to those coins of odd thickness quite nicely. With 3-4 staples that thing will be sealed tight and not move at all, so it will definitely provide you with more protection than just a plastic flip where the coin can move around, and best of all, it is a very cheap solution. Mine is so tight inside the lighthouse cardboard flip that I can shake the holder with my hand quite vigorously and that thing won't even move a millimeter. In fact, it hasn't moved at all since I stapled it in there 9 months ago.
Cheap way to get a "custom" Capital Plastic holder. Buy two of the 2x2 small dollar CP holders for each one. Now make a four layer holder instead of three using both of the inner pieces and two of the outer ones. Replace the plastic screws with binder posts. You can even get plastic binder posts if you want. It will still be a little costly, but cheaper than a true custom CP holder.
I also have one of these beasties and I keep it in an Eagle brand 2x2. The halves are hard plastic and the coin is held by peg-mounted 5 mil thick Mylar windows. Yes, the 5 mil is not offered any more; they have simplified down to 3 or 7 mil, and I wish I could get more Eagle 36 boxes for their 2x2's, but I still love their remaining products. The extra thickness of the piece makes it sketchy for the SBA/Sac sized holder, so I have it in one designed for the half dollar diameter. For another option: both Great Britain and France are fond of cranking out piedfort thickness coins from time to time, so a more likely thickness appropriate capsule might be found made by and for the European market.