The sheath

Part two of my companion dagger is the scabbard. I had a tough time with the sheath, well, tougher than I thought I would. There is a saying that goes haste makes waste. I found that to be truth in this project. It all went pretty well. I started off cutting three like pieces of wood and tracing the blade onto one. I cut it out using a jig saw and then glued the other two boards onto either side. a week later i came back to finish the job.

After i cut out the rough shape i finished it with a hand file. 

after a shaping with the hand rasp i used some 120 sandpaper and hand sanded it smooth. Next in the steps was to wrap some leather around it so i sewed it up, and skinned it. next i bought a length of conduit 1.25 inch in diameter. i cut and hammered it out flat. then i used the power sander to shape it final. 

After this I needed to make a cap for the tip, and here I ran into my snag. I started out just like the collar, cutting it out of the conduit and welded it together. The thing is the repeated welding and sanding and polishing and re welding and polishing made the metal too thin and too easy to burn holes in. the more i messed it up the more impatient i got, witch caused more fail. a vicious cycle. 

after a while it got to the point where i had to call it. ten hours work down the drain.

a week later i started over. i cut two pieces of sheet metal and molded them to the tip of the sheath and using a wire fed welder stitched the seams. than the sanding and polishing and filing of holes. luckily i managed not to burn any holes into it and got it done. each time i work something i get a little better and learn a little more. i think i still have some work to do on the tip but its acceptable to me for now.