Make a wooden insert for the knife sheath

When I make a knife sheath, I often use a wooden insert because it provides a completely flat surface and a more refined appearance. It also allows for decorations on the sheath that are not interrupted by the transition between the handle and the blade. The method for measuring the sheath is the same, whether or not you use an insert – how I make the template for the sheath can be seen in another post.

For the insert, I use a piece of hardwood, in this case maple, about 10 mm thick. I start by fitting the front of the insert to the handle. If the front of the handle is curved, I cut the insert to follow this curve, so it lies completely flush against the handle.

Once the front fits, I transfer the outline of the blade onto the wood with a precise pencil. Right at the handle, I mark the width of the handle and adjust the blade lines so that the transition between blade and handle is perfectly smooth and gap-free.

Once the lines are drawn, I cut the insert on a scroll saw so that it exactly follows the blade’s contour.

Then I place the insert on the blade and transfer the handle’s curve with a thin pencil, ensuring that the fit at the front of the sheath is precise.

The rough shaping is done on a rotary grinder, removing excess material, and the final adjustment is made with a file and sandpaper until the insert fits tightly along both the blade and the handle. The transition between blade and handle must be perfect, as even small irregularities will be visible when the sheath is sewn and finished.

The more precisely the insert fits, the more beautiful the finished knife sheath will be. It pays to be meticulous.