Kydex sheath too tight to be used, how can I fix it?

[CommanderandMaster]

I have a Windlass Steelcrafts Fairbairn Sykes replica that I bought a kydex sheath for; this one in fact, is the only one I've found for sale: https://armorsheaths.com/products/fairbairn-sykes-commando-kydex-sheath

When I received the sheath, I inserted the knife into it and while it had a bit of resistance, it went in fine. However, when I went to remove it, no amount of pulling and bending on the sheath freed the knife from it. It sat hanging upside down with a bit of 3 in 1 oil poured into the drain hole in hopes that lubrication would help free up the knife from the sheath, but any time I'd tried to remove the knife during that period, nothing changed, if anything it was made more difficult because the handle was slippery from the 3 in 1.

Today I decided to try something I'd read about while I googled around to find a solution, which was to drill out the top rivets of the sheath and try to remove it again. This time it worked, although I still had to loop paracord through the bottom rivets on the sheath, and tie it off to something, and give it a good yank to get the sheath to come away from the knife.

At current it still isn't easy enough to use as a sheath where I can remove it by just pulling up on it out of the sheath, does anyone have any advice for what I could try?

Also the reason I resorted to drilling out the top rivets is, I contacted the maker and he didn't respond to email or facebook messages at all, in the span of a few months between messages.

 

[elasmonut]

Kydex is heat moldable, simple answer put on some gloves, grab a hair dryer and gently heat the throat area of the sheath, then gently slide the knife in and out until the desired tension is required.
Watch some youtube vids on kydex sheath making, as you will want to replace those rivets too.

 

[David Brown]

here is a good video (not me by the way)

It is pretty easy to get down.

Just do not over heat.

If it gets too bad let me know I can make you a new sheath.

 

[David Mary]

I don't like that sheath, from the look of it. If I were to make a sheath for that knife, I think I would cut the Kydex quite a bit shorter and leave the quillons partly exposed. Probably use half the number of eyelets, too.

 

[elasmonut]

I don't like that sheath, from the look of it. If I were to make a sheath for that knife, I think I would cut the Kydex quite a bit shorter and leave the quillons partly exposed. Probably use half the number of eyelets, too.

View attachment 1579080

Yeah I agree. Less at the top, less rivets, a better attachment point for belt loop or clip....not a fan.
I say talk to David who posted the vid he knows what he is doin with kydex and makes some stellar stuff.