Ditto to all the aggravations mentioned by all of you. Like, Bruce, I can make a good functional sheath that holds together well over time, but it will not win any beauty contests. I did everything by hand because I did want want to invest in a stitcher/sewing maching. Of course, doing it by hand is pretty slow. In the time it took me to make a sheath I could profile, grind and heat treat another knife. I know, I was slow! I figured I was better off having someone else make them so last year I chose to farm out my sheath making to a professional and have not looked back. I do this for low-end knives as well. Even though there is some cash outlay with this process I felt I was money ahead in time savings and reduced aggravation. I pass some of the cost on to the customer and eat some of it myself as the cost of doing business. For me, this has worked well and the professional sheaths make my knives look better and I believe, have improved sales.
Fox