First, take your finished knife and put it on some newspaper, tracing paper, or whatever paper you use to make patterns with. I used newspaper. Then, trace out the back of the sheath. This will extend most of the way up your knife, tip to handle. Use a reference image! You can trace it exactly, then add seam allowance, or trace it with seam allowance. If you are a newbie sewer, seam allowance is the extra fabric added to a pattern for connecting the pieces. Newbies, give yourself a lot of seam allowance, like 5/8". Non-newbs, go with 1/4". I used a dark brown suede material for my sheath.
Cut out. This is your back piece. For the front piece, put the paper on top of your knife and trace.
These are your pattern. Keep these pieces after you make your sheath. If the sheath is ever damaged, or you find better material, or if you just mess up the first time around, you will have a pattern to work from. Next, cut out your fabric. You will need to cut 2 of the fabric for each pattern piece, and you will need to cut one interfacing (I used stabilizer) for the back piece. When cutting the fabric, I recommend folding the material in half, and double cutting like that. If you don't, you will need to flip your pattern for the second piece. This will hopefully make sense later.
Check time: You should have 2 fabric back pieces, 2 fabric front pieces, and 1 interfacing back piece. Okay, next step. Iron on the interfacing to the WRONG side of the fabric of one of the back pieces. I chose the back piece that will be against the knife, but it really doesn't matter. Follow the directions that come with your interfacing.
Now, with RIGHT sides together, line up your pattern. This is why you need to cut the fabric folded or flip your pattern. If you don't, your pieces won't line up correctly. You are now going to sew your pieces together, using the seam allowance you gave yourself. If you went with 1/4" like I did, then make sure your sewing is 1/4" from the edge. Don't forget to back stitch so you don't have to tie your threads. If you don't know what this is, google it or ask.
Now, you need to cut the piece that your belt loop will slide through. Decide what thickness you want. Then double that. I decided I wanted 1/2". So that makes 1" when doubles. Now, add seam allowance to BOTH SIDES, which brings the measurement to 1 1/2". This is your width. Then, decide how long you want it. I didn't measure this, I just cut until it looked about right. If you have a specific belt you are using, you may want to measure this, then add seam allowance to both sides. You only need 1 piece cut from the fabric. With RIGHT sides together, fold in half lengthwise and stitch. Turn right side out and press.
Now, attach to the back piece. Fold over the top to your seam allowance and stitch. Repeat for bottom.
Make sure you add the belt loop BEFORE you sew the top and bottom pieces together. Once added, fold your top raw edge on both pieces in, then sew. Basically, you want to trap the raw edges within your piece so they don't straggle.
I actually messed mine up a little, but I'm not really worried since it mostly isn't going to be seen. Now, you are going to attach your two pieces. Make sure the back piece is attached to the front with the belt loop on the exposed side (unless you plan on flipping it insides out, which I do not suggest). Sew together.
I actually found it easier to stitch one side, put the needle down into the fabric, lift foot, spin fabric and line up, then put foot down and stitch other side. But do what works for you. And we are finished! Test it out to make sure the knife fits in it, and that it fits on your belt.
Comments, questions, or request please leave in the comment section below.
Until next time, keep cosplaying!