method: overkill
(for larger blades)
cut one face of the end shorter than the otherside so you can bend it over, making a sealed end
folded reinforcement for the tip
leave enough room for the cardboard to taper when you roll/fold the longer side over
so that it wedges the handle downward. If the handle side gets slammed down, it has to shove the cardboard apart before it can get to the sealed end and break through.
final product. This way it's held in place within the sleeve by multiple points of pressure, and even if it does manage to slide up or down, it has extra room and reinforcements at both ends.
on a machete (with adittional handle stabilizer)
Because this machete doesn't have a lot of grip points for the rolled cardboard to keep it in place (from sliding up or down) I cut a window to help grip it into place. This way the handle gaurds will hit the cardboard here instead of having the tip fly through the package.
With this kind of sheathing overkill it's much less likely to puncture through the packaging box and less likely to get damaged as a result of it. With other types of products it's necessary to pad them and keep them from striking hard surfaces because it might damage the product. With knives this heavy, if the box is struck on a hard object or put through a lot of g-force on a curve, throw, spin or drop - you have an edge projectile that can and will cut anyone who grabs it without seeing it. My goal with packing knives is less about protecting the knife and more about protecting the people who handle it - as said before in this thread, who often handle it like a football.