I got a chance to build Joe's sheath today. I am still experimenting with different liners on these metal sheaths. There are some things in the process of building them that are contrary to the way a normal leather or kydex sheath would be made. With a leather sheath you are working with one medium, leather. With kydex, just kydex. With these, there is the liner material, the adhesive, the aluminum body, the leather cover and then the Ito wrap. I am having to come up with different processes to facilitate everything. If the paper lined aluminum were available, like Phill used, it would be a much more straightforward process.
Anyway, this is how I built Joe's sheath. Don't take it as gospel as I am still working out the best way/materials to use.
On the original sheath I used a Suede liner. While nice, it is a little bulky. On this one I wanted to try something else. I went with Dyneema Xgrid. It's a modern/high tech fabric that is waterproof, very tough and super thin. I think it will work out quite well.
Here I have used 3M 90 High strength spray adhesive on the fabric and Aluminum.
The fabric glued the metal.
Here is the sheath after I have formed it, and the bison hide that I will wrap it with.
Wrapping the leather around.
I punch holes in the leather before I drill through the aluminum. This makes for a much cleaner hole.
Here I have trimmed up the end of the sheath and installed the static line Eyelets. I tie the Ito on in way that it can be used as a static line, or you can attach one through the eyelets. Everyone likes options.
And the completed sheath. I soak the Ito in resin on the sheath to keep it from shifting around. It offers nice grip inside your belt.
I'll try and take some nice finished pics tomorrow before I get it shipped out to Joe.