Hi Scott!
First thing, in my experience, every Sifu I've ever handled snaps open so easily that any added "grab the thumbstud in kydex" complexity simply isn't necessary. A better idea is to just position the knife properly for a snapopen after the initial draw.
Maybe in a version done for something shorter, that might make sense?
As to leaving off the "pommel cap"...the whole idea here is that if you're rolling and sliding down the street post-crash, a hard wack to the top or bottom of the sheath won't dislodge the knife. Instead, it'll be driven into the bottom left or top right "locked down" corners of the sheath.
I already have one Sifu sheath that is NOT "crash resistant", see also:
http://www.ninehundred.com/~equalccw/blades.html - look for the two pics, bottom of page, plus there's links to the blueprints.
But now that I'm back on two wheels, the "belt slide" rig isn't adequate.
What else...as to that last paragraph, I'm not following you. I had assumed the 3 "locked corners" would be formed with little wings that fold back over the baseplate. Errr...in other words, the "pattern" to cut in the kydex before any folding or heating might look something like this:
(GOD I love Windows Paint
).
Once it's all folded and tabbed, you wouldn't need "extreme outline molding", especially on the pommel area. Although come to think, the tabs are going to need to be longer than shown here because the tab-to-tab horizontal distances will be shorter with the knife actually in there. Make 'em rectangular and about .5" to .75" long versus small triangles as shown, that'll do it.
Jim
[This message has been edited by Jim March (edited 10-24-2000).]