This will be my first November Project

[BrokenolMarine]

Got out to work on the sheath for the Hunter. Had a layout in mind so the project layout went smoothly. Nice to be in the shop with the music in the background. I will figure out some simple pattern and get that applied in the next day or so.

I use old cardboard to cut out the template. In this case, a priority USPS box. Laid out the idea, transferred to the leather and cut 'er out.

A straightforward sheath. I laid out the back panel and belt look in combination, then the welts, using an old clear tape trick.

51 welts.jpg

Then the top panel which will end just under the blade guard.

50 top panel.jpg

All the pieces were laid out on the leather, on the back side. They are laid out in reverse so they come out facing the right direction for a right hand sheath.

52 layout to cut.jpg

The only thing not cut out here, is a retention strap. I'll make that and add it before I sew it all together.

53 cut out.jpg

Of course, I'll tool that strap as well.

[BrokenolMarine]

Since I wasn't going to start on the sheath this afternoon, and I was "Already out here..." I decided to fix the little things that annoyed me about the finished knife."

Come on, you knew I was going to....

First up, was the small gaps at the copper accent. Miss T said she never saw them, and SHE is my biggest critic. There was a small gap on each side, one slightly larger, but still small, than the other. (I know, I know, but they annoy ME.)

54 annoying gap.jpg

The other thing is this small crack in the walnut. It's stabalized, and can't go anywhere, but it annoys me as well. Miss T didn't notice IT either.

55 a crack as well.jpg

In major projects, these issues would be fixed before I started to sand, but it was going to be my working knife. Yeah, it still should be, but (anal) I can't let it go.

So I start by taking one of the scrap off cuts I always save, and rubbing it across 80 grit sandpaper to conjure up sawdust like a magician. Yup, I'm good.

56 sand scrap.jpg

I collect the sawdust by tapping lightly... (VERY lightly) on the edge of the sandpaper, over a piece of painter's tape, and then pushing the pile together. I repeat the process until I have a decent amount.

57 collect sawdust.jpg

Then I force it into the problem areas and pack it in tight.. Once they are filled, I swipe a q-tip dipped in the walnut stain across them. I let the areas dry. I take some very thin CS glue and touch it to the area where it wicks into the gaps packed with the stained sawdust.

58 filled the gap.jpg

I filled the crack in the end of the scale as well.

59 filled the crack too.jpg

I left the repairs to cure and set up, and I'll come back later and re-sand the scales to 1000 grit, maybe 1500. Working knife, but it can look good while working.

[BrokenolMarine]

Spent about an hour sanding and polishing, she is looking good. Note the smoother transitions around the knife and the nice smooth line from the scale to the copper accent. The crack has become an accent itself.

60 sanded and polished.jpg

Next session will concentrate on the sheath.

[Hatchdog]

Cracks? Gaps? Huh? Only you see them but it’s fun for us to see how you fix them.

That’s one good looking knife in that last pic.

[BrokenolMarine]

Got out after lunch to start tooling. Still learning my maker's mark, and this one I put on the front as I plan to keep this sheath, even if I send the knife away. I have another blade blank like this and will keep the next one if this one makes a trip. I like the basket weave quilted pattern.

61 started tooling.jpg

Once I cut in the front piece, I cut in the upper area for the sheath back. I made the pattern flow up the sheath.

62 cut in upper area.jpg

I test fit the original welts and they didn't hold the blade tightly enough, or at the proper angle after a closer look, so I cut a better, improved welt.

63 improved welt.jpg

Now I could test fit all the panels.

64 test fit.jpg

Then I went to work to finish the tooling. NOT nearly as much work as tooling the knife display case.

65 both pieces tooled.jpg

Lessons learned over the years. I pre-dyed the pieces, so that after glue up, there wouldn't be spots that didn't take glue because of bleed out. The dark area inside is to protect the leather and so there isn't undyed raw leather showing inside. The undyed segments are places where the glue will go.

66 dyed prior to glue up.jpg

Left to dry overnight, will glue up tomorrow, then sew.

[BrokenolMarine]

The belt loop is already cut out, and I will have a retention strap, haven't cut it out yet. Tomorrow.

[BrokenolMarine]

Out this morning and added additional coats of black and red dye and let that dry, then a coat of contact cement to glue the top panel on in preparation to sew them together. Let the cement dry and we will be ready to sew.

67 glue up to sew.jpg

Using my Cowboy 3200, I sewed the panel in place and the belt loop to the back. I am still NOT that good with the machine and did the best I could. I am getting better. I left the extra space on the sheath to allow the room for the machine foot, and after sewing trimmed away some extra leather, then dyed the edges black. It's looking okay. Once she dries good, I'll antique everything and burnish the edges.

68 sewn and trimmed.jpg

[BrokenolMarine]

Out this morning. I burnished the edges of the sheath, then treated the leather with mink oil. I buffed out the leather then antiqued it. After the antique had a chance to dry a bit, I wiped away the excess then waxed the sheath front and back then added another coat to the front. Buffed and buffed for that light sheen. She is done.

69 done.jpg

The knife fits nice and tight and shouldn't need the retention strap, but if it becomes necessary later, I can add one. For now, she rides nice and secure, even if I turn the sheath upside down and shake 'er. Gimpy old Marines don't turn upside down and shake these days so I don't see the knife having a chance to fall out of this sheath.

I see my errors, but most won't. Other perfectionists will. Those of us that do, strive to improve. It's a good thing.

[Hatchdog]

“ Gimpy old Marines don't turn upside down and shake these days”

Ain’t that the truth.


Looks great and I think the sheath colors compliment the knife perfectly.