Dacks' Buildoff Project

[Michael J. Smith]

Looking good.

If anyone has a hint on how to get a buffing wheel into the little cut-out hole.......

Cut a slot in a piece of round stock (I use 1/8" a lot) and attach a strip of sandpaper in the slot. Put it in your Dremel. You can get a really fine finish this way depending on the grit you finish with. Upgrade to a Foredom when you get the money.

[P. McKinley]

I've had a couple busy weeks at work, but I did manage a bit of progress on the sheath.

Here's all the pieces and parts of this sheath:


I cut out the various components from the cardboard drawing to use as a template. Here I've checked the alignment before cutting out the welt:


Now I'm rough shaping the contours of the sheath mouth:


And, fine tuning the same area with sanding drums on my drill press. I then went on to hand files to get the fit perfect.


This piece of moose antler will be the post for the knife retention strap(or whatever the heck its called).


A bit later in the process after I turned the base and spent several hours hand shaping:


Almost there. The base will be cut down to about 1/8" thick and a screw hole tapped up into the post, like a Sam Stud. Then polished.


More later this evening maybe. Thanks for tuning in.

[P. McKinley]

I spent some time on the sheath today.

I beveled the belt loop flap for a smooth transition:


I stuck the leather to the slabs with two-sided tape so I could pre-drill the stitch holes on the two pieces that run down the center.


Back side done:


Once all the stitch holes were done, I used a small round Dremmel carving bit to cut in groove for the stitching on the inside faces only. I don't want any raised stitches in there touching and restricting the blade.


It doesn't have to be pretty on the inside, just functional.


Once all the drilling was done I stuck the slabs to a wood block and sanded the outer faces on a granite slab all the way to 600 grit.


Slap a bit of Tung oil on them.... two coats with 600 grit sanding between. These will also get a good buffing and possibly a paste wax finish.


I had to reinforce this little stud with a wide washer so I made a crude one out of hack saw blade. This will be hidden under the leather. I also tapped the base of the stud to receive the screw.


I also located the stud on the leather face.


I bored out a small pocket in which the stud screw-head will rest so all is flush and smooth when assembled.


I also did a bit of work on this little piece.


I finally got the leather dyed and edged, and a piece of barrel braid lanyard ready before I call it a day.


Almost there. I'm hoping have this done tomorrow night.

[RoyalM]

Your attention to detail is fantastic mate, it shames me and some of the stuff I try and wing.

Looking like a real contender for overall winner I reckon.

[Fiddleback]

You are an amazing craftsman sir. Wow!

[cardoso5fr]

Impressive work

[P. McKinley]

The final steps.....

First though; I wasn't happy with the shape of the little antler stud/post thingy, so I spent a morning doing another. This is roughed out with a hack saw from a solid block.


Getting there:


Now its time to glue on the doe-skin liner. This is the back side:


I left clean about 1/4" on either end of the wood case. I'll be cutting and folding a tab under the sheet, so I don't have a cut edge showing.


This is the front side. I stretched a portion of the center over a piece of wood.


Glue was painted on both skin and wood and the center pushed up into the slot. All the small creases on the inside surface were smoothed out. Finally, I carefully painted glue onto both surfaces, slit the skin and folded it down to secure it.


Once the two halves were attached, I evened out the sides:


I use high-tech jig to keep the sheath flat and level for this process. Ingenious eh?


Scribe in the stitch line:


Mark the stitch holes:


Drill 'um out:


Stitch it up..... well after a bit of edge contouring, stitch channel work, and some polishing:


I'm doing the whipping on the lanyard:


That's about right:


The causalities of war:


I followed with a good cleaning and polish for all surfaces and with that I can now say.....

This piece is DONE!!

I take it to a photographer on Saturday, after which I'll post the Grand Reveal.

I leave you all with this:

[clw3]

That's really cool! I can't wait to see the final!

[zekiel]

I think seeing this really brings home all the trials and decisions you as a maker have to go through and I loved seeing it. Thank you so much and it's turning out great.

[n1ftyneil]

This is utterly incredible, and completely intimidating. At some points in time I believe I have good attention to detail. Then I see things like this and realize I'm an impatient little sh*t

[bikergoody]

I am in awe of your workmanship!