Cool thread idea! This is a good topic for other knives too, not just kitchen cutlery. For instance, I've made two filet knives this year that didn't need sheaths because the client likes to make his own. A few times, I've sent finished knives to a well-respected kydex guy at the client's request, because I'm just not set up for kydex. Often a high-end buyer will want the specialty sheathmaker of his/her choice to make a beautiful carved/embossed/inlayed leather sheath.
For shipping knives without sheaths, I use the edge-protectors Stacy mentioned, held to the blade with rubber bands. Then I wrap that in stiff cardstock and tape it together (leave the cardstock longer than the blade, to cover the tip). Then it's business as usual... slip a business card/the invoice/some promo material on it, wrap the whole mess in bubble-wrap or several layers of newspaper/butcher's paper, tape it up and plop it in a box with lots of stuffing so it can't rattle around.
I make sheaths for the kitchen knives too. Works good and makes a good overall package to sell.
Lovely work! I've made similar leather covers because the client didn't have a block or magnetic strip, or when they did it was already at capacity. A simple leather cover looks great, and then it doesn't matter if the knife gets banged around in a drawer or lays out on the cupboard. They're about the easiest sheath to make, and you can make them tastefully-decorated like Mr. Ferry's, or dirt simple.
I like the simple plastic(?) covers like Stacy showed, but a lot of the ones I've found have some other manu's name on them. :thumbdn: I suspect a person could make the same type of thing out of thin kydex and form it to the bolster fairly easily. That way the whole package is handmade/custom :thumbup:
