Knife cuts leather sheath when removing knife

Out of curiosity, are you tucking the strap behind that extension on the belt loop when you unfasten the strap? That extension helps in clearing the retention strap from the blade when it is unfastened.

Kinda like this shown on a similar one I made for a TOPS knife of mine:

View attachment 2097078
Yep I'm tucking it but it falls out and gets in the way. I'm sort of ocd and those things annoy the heck out of me. It only takes a few episodes of it disfunctioning and I'm ready to change it.
 
I'm always afraid the knife will fall out of the deep pocket sheath. Is that a thing or do they just not fall out ever?
If it's Kydex and well conceived, the risk is zero, in the pocket and even as blade up neck carry (that small blue knife with its lip clip sheath is norm worthy, best ever I experienced). The shown leather deep carry sheathes are definitely made for belt carry on a dangler : the sheath aligns up freely with your body position so the risk of losing the knife is minimal. Also, such sheathes require a level of tightness which might be perceived as excessive when new but, believe me, leather will loosen and smooth out over time. If a leather sheath is safely tight after years, it was very well conceived. Back in the days, they probably just wanted a safe storage for the knife without requesting more complication, enjoy Wild Bill Hicock with his patch knife, "handle up" carry (some of you will identify the movie/ serie) :
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I use this from time to time, it's fun and quite satisfying, safe, too. However, my idea of a necker is "handle down" carry :
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