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Old July 13, 2014, 09:44 PM   #1
DIY_guy
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Project GLADIOUS

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/97G...S_MACHETE.aspx

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



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.)



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



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



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.







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.



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



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)





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



Then the outer edges are beveled and wetted and slicked round with a deer antler.


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.



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Old July 13, 2014, 09:46 PM   #2
DIY_guy
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So far so good. Time for a trial fit.







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.



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



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









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









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Old July 13, 2014, 09:48 PM   #3
zerobarrier
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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.
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Old July 13, 2014, 10:53 PM   #4
Derry 1946
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Very impressive!
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Old July 14, 2014, 04:00 AM   #5
Mp7
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Nice sheath.
Way too nice for the POS that cold steel has produced.
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Old July 14, 2014, 06:30 AM   #6
DIY_guy
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I dont judge. The owner is happy with the blade so I am too. It seems sturdy and well made.
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Old July 14, 2014, 07:45 AM   #7
hso
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The work and sheath are worth much more than the machete that goes in it!

This guy better appreciate that.
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Old July 15, 2014, 09:21 PM   #8
SlayerOfBunnies
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Quote:
Originally Posted by DIY_guy View Post
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.
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Old July 16, 2014, 05:08 PM   #9
Darkbob
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That is great work! Thanks for showing all of the steps. Really nice tutorial.
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Old July 17, 2014, 03:08 AM   #10
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Very impressed, very nice work and fantastic presentation!

I wish I could do such cool work!
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Old July 17, 2014, 03:58 AM   #11
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Very very nice work!!!
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Old July 17, 2014, 02:57 PM   #12
tiamat
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Quote:
Originally Posted by rtrwv
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.
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Old July 17, 2014, 11:02 PM   #13
Outlaw Man
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Quote:
Originally Posted by Mp7
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!

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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