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How to Make a Puukko Sheath

A puukko is a Finnish knife that looks similar to a filet knife. "Puukko" is Finnish for "knife." It has a thicker blade than fillet knives and is around 3 to 4 inches long. The handle is also around 4 inches and has rounded grip. Making a puukko sheath is a simple process using Kydex, a thermal plastic that can be purchased at hobby stores. You will need a piece that is 3/4 inch wider than twice the blade width and 1 3/4 inches longer than the blade to make a proper puukko sheath.

Things You'll Need

Leather gloves
Tape measure
Heat gun
Kydex, 3/16 inch
2 high-density foam pads, 1 by 6 by 10 inches
2 plywood sheets, 3/4 by 6 by 10 inches
C-clamp, 6 inches
Drill
Drill bit, 3/16 inch
Hammer
10 rivets, 3/16 inch

Instructions

- 1
  Blow hot air with your heat gun over your Kydex. The Kydex is ready for the next step when it starts to bend easily.
- 2
  Fold the piece of Kydex over the back of the knife blade and the first 1 1/2 inches of the handle. The Kydex must cover the blade completely with an excess of Kydex 1/4 inch away from the blade.
- 3
  Place the folded Kydex and puukko between two pieces of foam and place the foam between two pieces of plywood. Clamp the plywood pieces together so the clamp is positioned over the center of the Kydex puukko sheath. Let the Kydex cool for 35 minutes.
- 4
  Remove the knife from the press and measure 1/8 inch away from the blade. Drill 3/16-inch holes that are spaced 1 inch apart along the blade. Hammer a rivet in each hole hole. This is your finished pukko sheath.

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