Tag Along With a Gnome Day - AKA How They Are Made!

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Oct 17, 2011
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Tag along to work with a Gnome builder.

Disclaimer: This is not a how you should build thread, I find that I am often told I do things a bit different, backwards etc than what some may consider normal, or the 'proper way'. There are many ways and this is just my way of doing things.

Apologies in advance, The shop is in a bit of a mess. Getting things ready to move in June so things are a bit disorganized and it's driving me nuts. Well, more nuts.

Seatbelts fastened? Sweet, Blast off meatball!


Leather:

I could go on and on about it. I'm picky, seriously. Off the shelf stuff just doesn't work for me. All of my leather comes from Hermann Oak directly and is split from thicker hides down to one size so it is uniform from one end to the other and then I have the backs sanded so there is none of that fleshy crap like you will find from Tandy or low grade leathers.
In addition to that I only get the choicest part of the hide which is the bend and basically the center of the hide. The rest they just scrap, this saves me on shipping weight. 40 or 50 hides is heavy, Just ask my UPS guy, He hates my guts.



Smooth as a baby cows butt




Grab a few hand tools and...



A few bigger tools



One row of dies, I do not make one sheath at a time I would never get anything done at that rate. I do about 30 because that's about all the pieces I can remember what goes to what at any one time.



Chop, Chop, Click Click for a few hours



Hey Warrior...Progress. Currently drying a snake for you




Then we triple check all the pieces for each sheath and then segregate everything for dyeing the right color.



Suit up for battle, I know alot of people have that ah I don't care about no fumes attitude. I'd prefer not to be on a ventilator when I'm 60. Just weird that way.





Gotta dilute this stuff otherwise everything is basically dark brown when it's dyed. I dunk dye everything for uniform color throughout, Yes it uses ALOT more dye that way. Some people use the dobbers, I don't because that just surface dyes things and if you get a scratch later then it just shows white underneath.




Dyed and Drying





While they are drying I grab some clean gloves and a very tight knit rag and dye the edges of the smaller parts. This part takes some time and patience to do right.



Once everything is dried I give every single thing a good coat of 100% Neatsfoot oil, The alcohol takes alot of the natural oils out so gotta put it back in. It also deepens the color and makes it more uniform.
I usually do that at night so it can soak in all night and be ready to go in the morning, In the meantime I go play with other things.

 
Day Two

Welts, Glue, Loads of Clamps. Wear gloves Barge cement is a royal mother in law to get off.







Glued and Drying




So now that the welts are glued we head on over to even them up on the inside




Dust Collection was one of the best things I bought, cuts about 95% of it down.




A bit of sanding later and they are ready to glue in



Grab a few blades, some of them require pre fitting




Getting everything glued up





Glued now head back to the sanding station




Smooth! Now to dye the edges.




While the edges dry I usually throw the finish coats on the pieces laying around everywhere.




Grab everything then head on over to the assembly line

Punching holes for hand stitching. I'd never use this thing for actually stitching, it's entirely too fussy but as a hole puncher it pretty much has no equal.



Fitting hardwares and then finishing the edges



Couple Beckers for fitting, Couple extras in case something breaks. Plus I am taking on a helper after the move, finally, so I need more for them. Yes I am organized.




Bunch of blah blah blah later



Now just got to package things up and get everything in the mail, Then I go back and clean everything for the next batch. Yea I am a neat freak, Everything has a place. :D


Thanks for dropping by. Now get out. :D

 
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Holy cow, I didn't realize you did so many at once. Some nice equipment you have there. I'm stoked about the new sheath. Thanks brother, appreciate it.
 
Very impressive. The amount of detail is a testament to the quality of your sheaths.


My favorite sky storm sheath.

870bfaf1.jpg
 
I know yours is taking awhile, doing a little something extra with it and I had to do a practice run on it first but it is in the works.


Holy cow, I didn't realize you did so many at once. Some nice equipment you have there. I'm stoked about the new sheath. Thanks brother, appreciate it.
 
I know yours is taking awhile, doing a little something extra with it and I had to do a practice run on it first but it is in the works.
Take your time brother. No hurries, I appreciate you doing it for me anyways.

That's just a hell of an operation you have there. Nice tools, very organized. I like it. :thumbup:
 
nothing says being prepared like being over prepared :)

and now i know the #1 suspect in the "someone is buying all the old beckers, and doesn't care about price"

:)
 
man this is a really cool thread. I have a new found respect for all that goes into the sheathmaking process, quite an impressive operation you have there sky!

You do incredible work :thumbup:
 
That is some amazing content right there. Thanks a lot for sharing and taking us on a tour in your shop. Much appreciated! Great work man.
 
Only one Brute???? You sir, are slipping.

In the pic where you have the sheaths all glued up, I noticed that your belt loops aren't stitched yet. How do you get them stitched after that?
 
A- That was an awesome post. An amazing amount of care goes in to it and it shows in the end product.
B- I'm a complete dumba$S. I got about 3/4 of the way through when I realized you weren't actually making little leather gnomes. I was looking thinking "oh those must be the arms, and those are the body.......". OK. No Bladeforums until coffee.
 
While the pictures of the production process are impressive, the gnome wielding the BK9 with such small arms is more so.
 
Sir that is true artwork! One of your creations is on my list of most haves. One day that will happen. I also appreciate you taking the time to see what it takes to make one. Thanks.
 
After looking at this, my dilemma over what custom sheath I'm going to buy is over. You sir have my business. Very nice work.
 
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