How to Make a Metal Knife Scabbard

Draw an outline around the blade of your knife onto the steel plate, then grind the plate down to the outline using an angle grinder with the steel firmly clamped in your vice. Wear safety goggles while operating the angle grinder.

Trace this knife blank onto the thin nickle or place sheeting, then draw another outline around this one, 1/4 inch larger around all sides. Make two of these, then cut them out using your tin snips. These will become the two halves of your scabbard.

Clamp the knife blank into the vice with either side of the scabbard cutouts on either side of the blank, with the outline lined up to the knife blank. There should be a 1/4-inch overhang of scabbard material all around the edges of the knife blank.

Place a piece of scrap wood block on one edge of scabbard sheet, and tap it flush to the edge of the knife blank with a hammer. This should create a 90-degree bend in the scabbard material.

Tap the other side of the scabbard flush with the knife blade, overlapping the other side of the scabbard from Step 4.

Turn the knife blank and scabbard over in the vice and do the same to it as in Steps 4 and 5. You should know have two halves of your scabbard that will securely hold the knife in place. Check by sliding the knife blank out, and sliding your knife blade in, checking that it holds it securely.

Wrap the scabbard with a length of galvanized steel wire, starting at the top handle end and working your way to the tip. This will secure the two halves together, adding strength to your scabbard. Add a belt loop if you wish when wrapping the galvanized wire around the scabbard, which can be accomplished by inserting a leather or wire loop larger enough to fit your belt through then securing it in place by weaving the wire through it tightly to the scabbard.