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Tutorial: Leather-Covered Kydex Sheath for a Big Knife
A few months ago......Shane Womer contacted me about making a leather-covered kydex sheath for a khukuri. We went through many iterations between then and now, and what you will see today is the result.
Shane purchased a very stout 16.5" Chiruwa AK with a horn handle and brass fittings. It came with a nice karda/chakma set and standard black leather scabbard. What Shane wanted to do was be able to one-hand-draw the khukuri in a sheath that was also super-tough. Naturally, kydex and leather came immediately to mind. Kydex, because of its ability to be heatformed to shape. Leather, to add thickness, toughness and natural beauty. One other requirement was to make a "frog" to hold the sheath in an easy-to-draw position.
While there are a few tutorials floating around about leather-covered kydex sheaths, they are mostly for small knives/neck-knives and there are none (to my knowledge) for big knives - such as Shane's enormous khukuri.
Part of the reason this took so long - was having to set everything up. I would think that anyone with at least a beginner's skill level could create this same sheath in roughly 6-8 hours (not counting waiting time). Most of you will be able to do it quicker.
I am not a professional sheath-maker and this is probably not the best way to accomplish this sheath. However, I have had the fortunate pleasure of consulting professionals on the path to getting this done and what I think I have is a good amateur sheath that can be put together by the most rudimentary Do-It-Yourself-er.
Supplies List:
3-4 Sq. Ft. of 8-10 oz. Veg. Tanned Leather = $13
Foam pad (ie. sleeping pad, around 1/2"-1" thick) = $10
2 Sq. Ft. of Kydex - mine was ~1/8" thick - you'll want at least 0.090" = $6
4 Sq. Ft. of Plywood, scrap (or similar) = $5
Contact Cement (not rubber cement, but contact cement) = $4
Mink Oil = $4
Beeswax = $4 (I used parafin wax)
Waxed Thread - Brown = $3
3M Blue Masking Tape = $2
Sandpaper & sanding block - use ~180/200 grit = $2
Saran Wrap = negligible
Cardboard = negligible
Tools needed:
Hand Drill - variable speed is best (either cord or cordless)
1/16" or 3/32" drill bit (I actually used a #50)
Leather needles (1 curved, 2 straight)
Knife (to cut leather, trim thread excess, etc.) - you pick
Saw (for cutting the kydex)
Double Boiler (or similar - see pic in tutorial)
Kitchen Oven
Pinch Clamps - at least 4
Edge Groover (I think that's what it's called...)
Optional Tools/Supplies:
Edge Dressing
Buffing wheel - for final finish
Bandsaw - makes cutting the kydex faster (and messier )
Belt sander - for cleaning up & rounding edges (also messier)
I am not going to cover safety basics or shop basics, etc. Just use your head...ie, don't cut out the leather on your kitchen table...
A few months ago......Shane Womer contacted me about making a leather-covered kydex sheath for a khukuri. We went through many iterations between then and now, and what you will see today is the result.
Shane purchased a very stout 16.5" Chiruwa AK with a horn handle and brass fittings. It came with a nice karda/chakma set and standard black leather scabbard. What Shane wanted to do was be able to one-hand-draw the khukuri in a sheath that was also super-tough. Naturally, kydex and leather came immediately to mind. Kydex, because of its ability to be heatformed to shape. Leather, to add thickness, toughness and natural beauty. One other requirement was to make a "frog" to hold the sheath in an easy-to-draw position.
While there are a few tutorials floating around about leather-covered kydex sheaths, they are mostly for small knives/neck-knives and there are none (to my knowledge) for big knives - such as Shane's enormous khukuri.
Part of the reason this took so long - was having to set everything up. I would think that anyone with at least a beginner's skill level could create this same sheath in roughly 6-8 hours (not counting waiting time). Most of you will be able to do it quicker.
I am not a professional sheath-maker and this is probably not the best way to accomplish this sheath. However, I have had the fortunate pleasure of consulting professionals on the path to getting this done and what I think I have is a good amateur sheath that can be put together by the most rudimentary Do-It-Yourself-er.
Supplies List:
3-4 Sq. Ft. of 8-10 oz. Veg. Tanned Leather = $13
Foam pad (ie. sleeping pad, around 1/2"-1" thick) = $10
2 Sq. Ft. of Kydex - mine was ~1/8" thick - you'll want at least 0.090" = $6
4 Sq. Ft. of Plywood, scrap (or similar) = $5
Contact Cement (not rubber cement, but contact cement) = $4
Mink Oil = $4
Beeswax = $4 (I used parafin wax)
Waxed Thread - Brown = $3
3M Blue Masking Tape = $2
Sandpaper & sanding block - use ~180/200 grit = $2
Saran Wrap = negligible
Cardboard = negligible
Tools needed:
Hand Drill - variable speed is best (either cord or cordless)
1/16" or 3/32" drill bit (I actually used a #50)
Leather needles (1 curved, 2 straight)
Knife (to cut leather, trim thread excess, etc.) - you pick
Saw (for cutting the kydex)
Double Boiler (or similar - see pic in tutorial)
Kitchen Oven
Pinch Clamps - at least 4
Edge Groover (I think that's what it's called...)
Optional Tools/Supplies:
Edge Dressing
Buffing wheel - for final finish
Bandsaw - makes cutting the kydex faster (and messier )
Belt sander - for cleaning up & rounding edges (also messier)
I am not going to cover safety basics or shop basics, etc. Just use your head...ie, don't cut out the leather on your kitchen table...