Tutorial: Make a Kydex Knife Sheath

You will need:

• Closed cell foam
• 2 by 4 lumber the length of your blade
• Hide Glue
• Sheet metal shears or band saw
• 1/8-inch Kydex(R) 5.5 inches longer than knife blade and 1 inch wider than double the blade width
• Heat gun or propane torch with fan tip
• Heavy leather work gloves
• Wrap-around eye protection
• Power drill or drill press, 3/16-inch bit
• Quick rivets
• 80 and 120-grit sandpaper

Step One:

Make a pressing block by securing closed-cell foam to a 2-inch by 4-inch block the same length as your blade, using hide glue, as in Figure A. Allow to dry.

Figure A

Step Two:

Use sheet metal shears to cut a rough sheath outline as in Figure B. Belt loop portion needs to be at least 4.5 inches long. Blade cover portion must be 1 inch longer than twice the blade width plus one inch.

Figure B

Step Three:

Use heat gun or torch to heat Kydex. Avoid scorching. Figure C shows the fold lines to use. Fold blade cover over blade of knife as in Figure D. Press with pressing block. Allow to cool. Heat loop area and bend to form belt loop.

Figure C

Figure D

Step Four:

Use shears to cut the Kydex around the blade as in Figure E. Leave 1/2-inch margin for rivets.

Figure E

Step Five:

Drill rivet holes with 3/16-inch bit as in Figure F. Attach quick rivets using manufacturer’s instructions as in Figure G. Sand edges with 80 and 120-grit sandpaper to remove any burrs.

Figure F

Figure G

Figure H Neck Knife Sheath

Use the knife profile in Figure H to make a neck knife. Add a lanyard hole to your Kydex sheath as shown, by eliminating the rivet at the knife tip end of the sheath.