Hey Firebat....
you guys got it down pretty good...
The use of petro jelly or Grease,, heavy oil and any of that jazz is probably the worst advice anyone has given on sheathmaking.
Put a little on your finger and go touch something with it....It will pick up all kinds of little pieces of crap and transfer them into your sheath....
I use only WD-40 and Snap silicone spray on my sheaths... The snap gets a rince after being introduced into the sheath,,Its only purpose is to make the mouth of the sheath a little slicker inside...
Don't even get me started on magnets in synthetic sheaths...
The sheath when you are done making it needs to be clean, clean, clean inside,, before you even start on eyelets..
The sheaths I do for my clients get at the Very least two high pressure washings..One before the eyelets go in and one after final fit and finish.. Belt loop is usually the last thing that goes on...
I've actually found grit embedded in the plastic of sheaths.. I have a couple of theories on how this happens..
The first is when you are pressing the knife.. If your work area is not clean before you tape, you can easily pick up and transfer a piece of grit onto you tape. When the knife is being pressed that piece of grit gets transfered Directly on and even into the hot plastic,,and thats where it will stay...
The other is that it comes from the factory like that.. Dirty machines,, kydex pellets spilled then swept up from the floor and dumped into the hopper,thus all that dirt gets into the plastic, and eventually into your sheaths....
Take you most polished knife and rub it like a madman onto a piece of raw synthetics.. You won't find scratches,,only scuff marks,,which are fairly easy to wipe off...
I hope that this explains things a little better...
Any sheathmaker worth his salt will know all this stuff, and be able to prevent it with a few simple tricks....
Any questions,,drop me a note..
ttyle
Eric...