Anthony.
You are welcome to message me, or even call me any time. You have been very generous with your time and kindness for my efforts. I appreciate that.
The belt loop, for me, has been a work in progress.
I started with a sort of Sheild Design - and frankly - I still think that looks the best. But the arc on the top was going to get a lot of stress (perhaps the stitch with the most stress on the design) and it bothered me that it was nearly a straight line. So - I took it out. My thinking was that it wouldn't tear out (essentially - less holes - better).
However, I have always thought the circle stitching on the belt loops was, in my mind, the superior design. I just couldn't do it very well. Then, on ebay, I found a circle stitch marking template. Gave you the option of 5 6 or 7 stitches per inch. Gave it a shot - and MAN - That was it. It sort of melded the awesomeness of the circle's strength with the utility of having a nice rounded stitch to allow the sheath to cantilever.
I know, geometrically, and physically, it is a superior design and I have not seen a weakness in carrying one.
This case was tough - and a compromise. I didn't have much real estate on the back of the case for a belt loop so although I wanted two circles - I settled for partial circles that left 1.5 inches for the belt that I knew Phil (the customer) normally wore.
That is my thinking. I am always open to suggestions and ideas from people I respect and trust. And, on this sub forum, that is essentially everyone. I owe a great debt to the teachers on this board.
EDIT:
Yes sir. I am still using a Utility knife to cut my leather. If it is good enough for the venerable Chuck Burrows - it is good enough for me. Although - I am going to give a standard clicker (trim) knife a shot in straight blade and curved. I am using a similar knife when I carve spoons - so I think it will extend to the bench as well.
TF