Project GLADIOUS


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DIY_guy
July 13, 2014, 09:44 PM
I was contacted by a fellow from another forum and asked to make a sheath for a sword he bought. I had never made a sheath for a sword before so I decided to take on the job. He asked me to make a leather sheath for his Cold Steel “Gladious” sword. (see link)

http://www.coldsteel.com/Product/97GMS/GLADIUS_MACHETE.aspx

At nearly 2 pounds its an impressive piece but sadly it comes in a canvas and plastic sheath.

http://i182.photobucket.com/albums/x285/newscouts/sheath994_zps813c43ed.jpg

He wanted something a little more in keeping with the era (more “period”). Right away I could see all sorts of potential for Celtic stamping and ornate carving but he would hear nothing of the sort. He wanted it plain, an everyday foot soldier sort of look to it with nothing fancy. I was bummed out but it’s his sword and I have to respect that.

The sheath that came with the sword and the typical wrap and snap like so many knife sheaths have but modern snaps would also not have been in keeping with the time period so I needed to find another way to keep the sword in the sheath with the leather I had on hand. I am using 8 Oz tooling leather (about an 1/8 of an inch thick.)

http://i182.photobucket.com/albums/x285/newscouts/sheath1_zpsaaf14bf3.jpg

Step one was to create a design and then cut out all the pieces of leather with a razor knife.

http://i182.photobucket.com/albums/x285/newscouts/sheath2_zpse4e53b3f.jpg

All the pieces are positioned and tacked in place with contact cement so they don’t shift while hand stitching.

http://i182.photobucket.com/albums/x285/newscouts/sheath3_zpsc56cffc9.jpg

The welt is sandwiched between the front and rear portions of the sheath and is equal to the thickness of the sword blade otherwise a blade this long would get pinched/trapped in the leather and the blade edge would cut all the stitching during insertion.

http://i182.photobucket.com/albums/x285/newscouts/sheath4_zpsf7ddbef4.jpg

http://i182.photobucket.com/albums/x285/newscouts/sheath5_zps41b8de0c.jpg

http://i182.photobucket.com/albums/x285/newscouts/sheath7_zps57653349.jpg

The features of the front face are stamped and stitched since it would be impossible to do so after the front and rear of the sheath are joined.

http://i182.photobucket.com/albums/x285/newscouts/sheath6_zps23f0e07e.jpg

Then all the stitching holes are stamped through all the layers.

http://i182.photobucket.com/albums/x285/newscouts/sheath8_zps5c9e3985.jpg

Then lots and lots of time stitching by hand. (and with a pliers because this sheath is over a half inch thick to prevent that needle tip of the sword from coming though the leather)

http://i182.photobucket.com/albums/x285/newscouts/sheath9_zps856e4671.jpg

http://i182.photobucket.com/albums/x285/newscouts/4f18ccf3-e12e-4046-9e3e-d8b5ad4d5a5d_zpsd980119d.jpg

After stitching the final trim is done with a razor knife.

http://i182.photobucket.com/albums/x285/newscouts/e613e780-de36-462c-8ede-210427017a73_zps35e268aa.jpg

Then the outer edges are beveled and wetted and slicked round with a deer antler.
http://i182.photobucket.com/albums/x285/newscouts/b7e476af-559e-4f30-ab45-8206fca1b3e1_zps13f9a6a5.jpg

The sword will be kept in the sheath with the two integral leather straps but feeding the straps though the openings will be tough so I tapered some wood blocks and wetted the leather to mold and lock in a shape. The wood blocks are tapered to a zero thickness that allows the straps to be fed in but still afford the friction at the lead outside to hold the straps securely.

http://i182.photobucket.com/albums/x285/newscouts/sheath93_zpsf2b621a8.jpg

http://i182.photobucket.com/albums/x285/newscouts/sheath94_zpscb71afab.jpg

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DIY_guy
July 13, 2014, 09:46 PM
So far so good. Time for a trial fit.

http://i182.photobucket.com/albums/x285/newscouts/54be1ca3-fd7e-40f0-893d-77a96bc7b164_zps6c0119a8.jpg

http://i182.photobucket.com/albums/x285/newscouts/596e04dd-0b90-458f-b0ab-140fdceb93a7_zps4104fefb.jpg

http://i182.photobucket.com/albums/x285/newscouts/sheath98_zps79b56fcf.jpg

I wanted the sheath to have a distressed/antique sort of feel to it. I did a little mixology with denatured alcohol and a few colors.

http://i182.photobucket.com/albums/x285/newscouts/sheath99_zps02170681.jpg

After drying I gave the sheath a few applications of warmed mink oil to waterproof.

http://i182.photobucket.com/albums/x285/newscouts/sheath991_zps56d6fe0d.jpg

Then I turned to the grip and wrapping it with leather.

http://i182.photobucket.com/albums/x285/newscouts/sheath997_zps71a7c6fd.jpg

http://i182.photobucket.com/albums/x285/newscouts/sheath996_zpsb41bbb91.jpg

http://i182.photobucket.com/albums/x285/newscouts/sheath998_zps7be27cdb.jpg

http://i182.photobucket.com/albums/x285/newscouts/sheath999_zpsa36d3456.jpg

Project Gladious is finished and ready to return to its owner.

http://i182.photobucket.com/albums/x285/newscouts/sheath9991_zpsa31dd538.jpg

http://i182.photobucket.com/albums/x285/newscouts/d42b4d7c-f0c4-4b6c-9d1a-34f3304888d9_zpsbb6c4087.jpg

http://i182.photobucket.com/albums/x285/newscouts/sheath995_zps50a56dbe.jpg

http://i182.photobucket.com/albums/x285/newscouts/sheath992_zpsb284136d.jpg

http://i182.photobucket.com/albums/x285/newscouts/d1426524-142f-4d87-b487-5c4dbafaab0a_zpsc7e55094.jpg

zerobarrier
July 13, 2014, 09:48 PM
That's pretty cool. I want one now. I really want one. You did a real nice job. You should make more leather stuff and sell it, if you don't already.

Derry 1946
July 13, 2014, 10:53 PM
Very impressive!

Mp7
July 14, 2014, 04:00 AM
Nice sheath.
Way too nice for the POS that cold steel has produced. :scrutiny:

DIY_guy
July 14, 2014, 06:30 AM
I dont judge. The owner is happy with the blade so I am too. It seems sturdy and well made.

hso
July 14, 2014, 07:45 AM
The work and sheath are worth much more than the machete that goes in it!

This guy better appreciate that.

SlayerOfBunnies
July 15, 2014, 09:21 PM
WTH? What knife comes without a sheath??? How do you transport it for usage?
Not that the Cold Steel gladius is high end, but lots of high end knives - for instance Busse and Busse-kin - come without sheaths. Turns out that if you provide nylon sheaths, people whine that they aren't kydex. Provide kydex and they want leather. Give 'em leather and they want nylon.

Darkbob
July 16, 2014, 05:08 PM
That is great work! Thanks for showing all of the steps. Really nice tutorial.

rtrwv
July 17, 2014, 03:08 AM
Very impressed, very nice work and fantastic presentation!

I wish I could do such cool work:banghead:!

Centurian22
July 17, 2014, 03:58 AM
Very very nice work!!!

tiamat
July 17, 2014, 02:57 PM
Very impressed, very nice work and fantastic presentation!

I wish I could do such cool work!

Have you tried? never know what you can accomplish until you try.

Outlaw Man
July 17, 2014, 11:02 PM
Way too nice for the POS that cold steel has produced.
What are you talking about? It'll decapitate cardboard zombie targets and slice through two 2-liter bottles in a single swipe! :D

In all seriousness, the machete, in it's factory form, doesn't attract me at all. This sheath and leather handle wrap makes me want one.

Nice work!

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