Cliff,
Sounds like you are not giving yourself enough room
You might wanna try this...I use 10oz leather for the big blades BTW...Belly leather is fine for purses...Of course I use double shoulder leather for PURSES!!!!muahahahahaahahahaa<~~~~demented laugh!
make the tracing of the bowie slightly BIGGER...I use a compass and eye it in, but when I have the problem that you are having, I just make it a tad "bigger" and the problem goes bye bye....And since I almost sliced my hand off with one of Steve's blades I pay very close attention to this
now here is the slightly annoying part..
At the bottom of the sheath where the blade is gonna rest instead of following the outline of the sheath to make your welt, draw a line a little above the welt and cut it...Think of a welt with a upside down "V" at the bottom instead of a dip...Feel me??
make a kydex press (there are a hundred tutorials)
When you cut the foam...Cut 2 pieces of foam that are around 4 inchs wide and 6 inches long..(these go over the handle area)
hmm dont know how big my press is, but I "think" it is around 24x24..Will measure tomm if ya need me to..yea I made it big for those Khuks we all like so much..lol
GOTO harbor frieght and get some of those quick clamps...err around 5-6 should do the trick...C clamps will work (with a support), but I am lazy!!
After you have assembled the sheath (it will look bigger than it should), wet it like ya normally would..
wrap knife in seran wrap and tape the blade
shove it in the sheath until you get around an 1" or so of handle to giveit something to hold onto..
lay it in the press ON TOP OF one of the small strips that I mentioned earlier...lay other piece on top of handle
Clamp the CRAP out of it!!
Wonder off and drink beer or in my case chase 4 year old and drink Diet Sierra Mist free
Come back after a few minutes and check the tenstion on the clamps...Give each a little sqeeze..
Drink more beer or chase child...whichever applies
Repeat adjusting clamps until you catch child or fall drunk to the ground screaming about the liberal agenda..
After awhile you will have a perfectly formed and fitted sheath to your knife...HOWEVER...do NOT remove it from the sheath..you can "wiggle" it a little but leave it alone and let it dry completely!!!
It also helps if you take a scrap piece of belt stock and stick it in the belt slot on the sheath when you do this...Gives it that little nudge that customer's like so good
Any help I can give PM me
45-70...If you need some 10oz lemme know
There is no spoon!!<~~~which movie am I quoting??