Sidewinder-
I have been carrying my AR in the sheath from TAD for almost a month now, and it fits very well. The box shape of the sheath when it expands for the knife goes in fits perfect, and the pivot end of the knife sticks out about 1", and then the long flap folds over, and fits snug, but still comes out easy when you lift the flap. I thought the knife would be too big for it at first also, but when it slid in easily, and came out easily, I went "far out". After a couple of days of wearing the flap just naturally forms to the length of the knife, and has a nice bend in the flap to conform to it.
Larry