On Monday afternoon I finished molding and then sanding my homemade kydex sheath for my Enuff. On Sunday night I had done the basic cutting of the kydex and some of the heating and shaping, and then I did the riveting.
Here's the thing (and you can see in the photos): the finished sheath has four rivets. When I first started the sheath, I had six
rivets. But I found (and this isn't the first time it's happened) that the two rivets closest to the opening were too
close to the opening, and that prevents there being enough length of kydex to flex open and admit the knife.
I was pretty dismayed. I had already invested a good bit of time by that point. So I attempted to salvage the project, and I ended up succeeding. I cut off the top part of the sheath with the top two rivets and -- for the first time ever, tried to see what would happen if I heat-formed the sheath with the rivets already in place. I used to think that it wouldn't work. Now I know better.
I heated the four-riveted sheath with my heat-gun and slid the knife into it, and using a combination of foam pads and suede-gloved fingertips, formed it to the knife. Here's what it looked like at that point.
On Monday, I proceeded with cutting away excess, sanding edges, and then adjusting the fit and tightness. I am a fiend for tight-retention kydex. Rattling is not acceptable. Easy withdrawal is not acceptable.
So it took a good few hours (since I'm not an expert, and I am working with a very under-equipped kit and workspace) to get the fit correct. At that point, I did a little more sanding, and then took the Tek-Lok clip from my Moran Featherweight and drilled a couple of holes and attached that.
Here is the result. It is a very serviceable sheath, holds the knife nice and tightly, is a little bit of a challenge to re-sheathe, but that's ok with me. It rides comfortably on my hip. The little curved dips beside the knife on the left and right have purpose. The one on the blade side is there to help the tang of the blade make it inside (it's really a carve-out to open up the aperture). The one on the spine side is there for thumb pressure to help unsheathe the knife.
The flat of the blade has taken on some scratches from the sheath. I can live with that.
I am planning on getting this professional-grade foam kydex press as soon as I can, because it will make this kind of project about 500% easier and quicker. Click for link to Kydex press