Home >> Hobbies >> Other Hobbies

How to Make a BK-9 Sheath

The BK9 is a Bowie knife with a 9 1/4-inch blade. It is made by Becker Knife and Tool, and was made for survival situations. The knife comes with a cordura sheath when it is purchased retail. An option for making a alternative sheath consists of using a heat-moldable plastic, sometimes referred to as thermoplastic. This material is molded over the knife with the assistance of a heat gun.

Things You'll Need

Leather gloves
2 heat-moldable plastic sheets, 1/8-by-3 1/2-by-10 ½ inches
Heat gun
BK9 Bowie knife
Foam pad, 1 1/2-by-12-by-12 inches
2 plywood sheets, 3/4-by-6-by-12 inches
2 C-clamps, 6-inch
Tape measure
Drill
Drill bit, 3/16-inch
Hammer
22 grommets, 3/16-inch
Band saw

Instructions

- 1
  Heat the moldable sheets until they are malleable. Place the knife blade between the sheets, and completely cover the blade. The top portion of the handle must be covered by 1-inch of heat-moldable plastic.
- 2
  Fold the foam over the heat-moldable sheets; the knife must be covered. Place the foam between two sheets of plywood. Line up the edges flush. Clamp down the plywood with your C-clamps. Space the clamps 4 inches apart, 3 inches away from the 12-inch edges of the plywood. This captures the shape of the knife in the plastic. Let the plastic cool for 30 minutes.
- 3
  Drill 22 holes spaced 1 inch apart and 1/4-inch away from the crease in the plastic caused by the knife. The holes must be of a 3/16-inch diameter. Pound a grommet into each hole and cut off any undesired plastic using your band saw.

Other Hobbies