A little work in process

[Gary W. Graley]

Working on a few sheaths this week, here are some images of the steps
as I work through making them;
The knives are
Spyderco Szabofly, strange butterfly knife but cool
Benchmade 43
Bose/Case Dogleg

the above are the start of the sheaths being formed using the bone folder
note on the Dogleg sheath there is a section cut out to allow the leather
to fold down and around the knife, on the horizontal sheaths, that's not
necessary as the leather doesn't wrap around, BUT, it does take TIME and
pressure to work the leather around the knife in order to make it fitup as
it needs to for best retention.
More images next post, software limits the number per post
G2

 

[Gary W. Graley]

I use a brick size block of steel as a base and then a smaller bits of metal
to use as the anvil that goes under the leather to emboss;
Here you see the block of steel, the top section of the sheath, the embossing
stamp and the handle that sets on top.

Then I take the top section and knife, lay it on to another piece of leather

Carefully remove the top section without moving the knife and draw around
the knife so I know where I will need to sand and then apply the glue;

very important to rough up the area, otherwise the glue, I use Barge cement,
will not 'set' properly into the leather;

apply to both the base and the top section, allow to dry and then
I set the knife inside the top section and carefully rest it down onto the
base piece and rub around with the bone folder tool to press the two
pieces together.

the Dogleg is now glued up and hand sewn up and rough trimmed
next will be out to the shed to sand down the edges

More as they go through the process, next step will be to hammer in the
holes around the sheath and then to trim the top side...
G2

 

[Morrow]

Very nice...you make it look easy.

 

[Gary W. Graley]

Thanks, a couple of tips that might help others with their embossing

Work on a solid base to help prevent any bouncing

Press down while gripping the handle, also prevents any skipping or double striking

I work the embossing stamp first a hard hit straight down
then I work it to each corner to help set the embossing deep
BUT, becareful not to let the very edge of the stamp mark the
leather, that takes some time to learn, also depends on how tight
grained the leather is you are working with.

after you dye the work, go BACK and strike the embossing a second time, because
when you dye it, the leather will bloom back out a little,
so striking again it will help to make a very crisp embossing...

G2

 

[Dusty One]

Great work. Thanks for showing the steps. When I need a folder sheath I know where to look.....

 

[JB in SC]

Gary that Dogleg has some nice pants

 

[JParanee]

Gary this is just fantastic it is so cool of you to take the time to show us your art. What makes it even better is that two of them are mine..

 

[338375]

Those are great pics Gary... Great workmanship as well :thumbup:

 

[TekSec]

Yet another great post, G2! Love to see the WIP. I'm fascinated with the embossing, they look so perfect! Keep up the great work.

 

[Brian Jones]

Okay, first photo. Are those sheaths designed to be worn on belt, front of pants?

Sorry....


Seriously, Gary, I have watched you doing this since you first started and you have become a master craftsman -- it has been fun and amazing to watch your progress!

 

[Gary W. Graley]

Thanks guys and Brian, you could 'slip' into your front pocket if needed

I get a lot of that from work when they see these before I ship them out
they're like Hmmmm how did you form those again? lol yeah, I know...
G2

 

[Sam Salvati]

WOW Gary, great work thanks for the in progress shots, very cool.

Was nice to meet you at Ashokan this year, your sheaths are amazing.

 

[Greg45]

Amazing work, as usual!

Thank you for posting this and your other work.

 

[nikoknife48]

Great craftsmanship Gary thanks for sharing the process!! Can't wait to see the finished design.

 

[StretchNM]

As always....simply.....outstanding.

 

[John M Cohea]

Cool thread Gary, Your molding of the leather is as crisp and tight as I guess I have ever seen.

 

[Gary W. Graley]

Thanks guys, I try to put as much info along with the shots so those just
starting out will get an urge to give it a try and these may help.

Here are a few more shots, sheaths are about finished tonight, will do the
final edging and a coat of Atom balm wax and pack em up on Thursday.
I've been on vacation the last week and the past two days so I had some time
to spend, it's back to the grind tomorrow though

I use a cut down 4 prong, it broke a long time ago and so I use it to 'walk' around
curves when I'm putting the holes in the top section of the sheath;
I've tried the spur wheely thingys but on tight projects like these they often don't
work as well as this method and sometimes those wheely things have a mind of their own
and you over run the track you really wanted, so for me, this works better, sometimes
I will lightly pencil in a line to follow with the stitching prongs just to help me stay on track

then I cut along the top edge as that is the side that will be glued to the next piece
that forms the belt loop and I can't cut on it once it's glued down, so a close cut here
and then sanded down to a smooth edge

then the third piece of leather will be glued along the full length of the knife sheath
and part of the top will be trimmed narrower to fold over and become the belt loop, here
I had marked the leather and dye just inside the line

same applies here as before, you need to rough up the leather so the glue will adhere

once glued in place, I go around with a makeshift awl ground from and old screwdriver
and punch through the holes, as there are now three layers of leather

then I'll hand sew along the top border and around the end and then trim the piece that
will fold over to become the belt loop

and finally here is a shot about 90% finished, need to smooth the edges on the three
bali sheaths and coat with the wax, the dog leg sheath is done and great snap in retention
due to the shape of the blades, nice knife and now a handy carry, this one is vertical
where the other three are horizontal, the one with the cross will be worn on a wide
belt, 1 3/4" the other two are fitted for 1 1/2" belts.

Thanks for watching and I hope this sparks some interest in getting knife and leather and
going at it!

G2

 

[nate3993]

very nice work

 

[rayban]

Thanks guys and Brian, you could 'slip' into your front pocket if needed

I get a lot of that from work when they see these before I ship them out
they're like Hmmmm how did you form those again? lol yeah, I know...
G2

I thought I was the only pervert here......very nice work, always nice to get a lesson from ya.:thumbup:

 

[Dixieblade57]

Really fine work on those sheaths. :thumbup::thumbup:
I've got to ask a few questions if you don't mind.
What weight of leather are you using? I would guess it's close to 10 oz.

How in the world are you getting such great form around the knife itself?

In the past I have been able to get shape, but nothing even close to the defination you are obtaining. It looks like it has been vacum molded around the knife!
How wet do you get your leather to form it and how do you keep it in such tight shape to the knife?

I would love to hear a little more about how you are doing such defination of the knife shape itself!
Great work!!!!!