Let's build a bowie for TEOTWAWKI

[D.Ellis]

I am just using a modeling tool to make the design here.

 

Here using the other end of the tool to add some different grooves.

 

Getting ready to mark for the stitching. Here you can see the stitch marking tool on the left and my home made one on the right. I wanted a bit more room between stitches so made this one up a few years back.

 

Marking for the stitching.

 

[D.Ellis]

Using the modeling tool to clean up the border.
   

Putting the belt loop on the back with a copper rivet.

   

And mounting the stud button on the front. You can see how rough the flesh side of this leather is. For this reason, and also to cover the screw head and rivet back, and to add stiffness to the sheath, I am using an extra layer of leather on the front and back. Pics will make more sense than my rambling.

   

After using the cardboard template to make the 4 layers, I then cut out the tracing of the blade............

   

And use it to mark for the welt.
You can see the 2 layers of leather front and back. Also notice I have dyed the welt and inside top of the sheath before I get glue on it. The dye will not take where there is glue residue.

   
]

[D.Ellis]

Glue in the welt in place using contact cement.
 

And here it is all glued up and ready to drill for the stitching.
 

Drilling for the stitching with the drill press. Trick is to keep it flat so the row of holes on the bottom is straight.

 

Grooving for the stitching. This protects the thread from abrasion by keeping it below the surface of the sheath.

 

[D.Ellis]

At the top of the sheath for 4 or 5 holes I have grooved the leather deeper as this is where the stitching will end and it needs a bit more room there.
Moving on to the color. The sharpie works well to make a clean transition between the black border and the brown tooled area. I have trouble keeping the dye from getting away so this step buys me a bit of leeway.

 

Coating the tooled area with antique finish. I slopped a bit over the line in a couple spots, but it will not matter as that's gonna be black later.
 

Wiped the excess antique off the tooling, and dyed the edge(and the back and belt loop) black.
 

Beginning the stitching. I am using artificial sinew. The rule of thumb is 7 times the length of your stitching for this style stitch. I decided that I'd do this in two pieces since 7 times 28 inches is a bit long to handle. Fold the sinew in half and the first half goes through like this.
 
And the other end follows it but down for up and up for down.
 

[D.Ellis]

Get to the end and I tie an overhand knot like so on the back side of the sheath.

 

And then the needles go back down the hole closest to them.......and continue stitching back towards the starting point again.......for a few stitches. It gets tough to get the needle through so I grip the needle in the pliers and push on the pliers to get it started. Then grab the tip of the needle and pull it through from the other side. A couple things of note. The needle points have been blunted and polished to make them less likely to cut into the thread, but it helps to aim the point of the needle to the side of the hole so you do not damage the thread that is already there.

 

After a few stitches I cut off the sinew short on the backside of the sheath and melt the ends with a lighter. Use the side of the flame so you can get close to the sheath without burning anything you don't want to.
 
Here's what you get......little melted ends that resist backing up into the holes.

 
Then I stitched the other half of the sheath same way. After that I clean up the horrible looking welt with the belt grinder, and bevel the edges.
 

[D.Ellis]

I got the sheath done now, but still need to take final pics.........tomorrow, I'm beat!    :D  
Darcy

[Lin Rhea]

Take a rest. You done good.

This is a very nice tutorial. One of the best I've seen. The photos are great too. You get high marks all around.

[akaboomer]

Very nice all around. Darcy, thanks for the time and effort you put into this.

Chris

[D.Ellis]

Thanks guys. I got a couple final pics done this morning. The sheath angle is adjustable and made to work in a cross draw style. The blade is too long for this half breed, (hobbit/garden gnome)to draw from the right hip........cross draw works well for this.
 

 

One of my hound pups decided to lessen the ugliness of this pic for me.    Thanks Dottie.
 

I hope you can all make some sense of what I wrote, I am not always able to make myself clear in a written format.........or in person for that matter.  :D  

Darcy

[bculberson]

Excellent tutorial Darcy.  
Nice blade and sheath!

[tomsm44]

 

Well worth the wait.  When you do mine, send it my way with a shoulder rig though.  I enjoyed every bit of this tutorial and hope to steal    a few of your techniques over the next couple months.

[JMR]

Great tutorial! I really like that knife and even though I don't believe in zombies I would love a knife just like that. You know "just in case" I'm wrong! Lol

[D.Ellis]

Thanks guys.
Matt, I steal most of my techniques as well so steal away. Let me know if you have any questions about a procedure.........I may have already goofed it up a time or two and can save you the headache.  :D  
JMR, you can't be too carefull with zombies eh!
Darcy  

[Izzy]

Talent, plenty of talent.  

[South MS Bowhunter]

Darcy,

Thank you sir for the time and effort you put into the how to, don’t know if i’ll ever build a knife but the effort has not gone unappreciated!

[Steve Nuckels]

Great project Darcy!  I love the sheath & Knife!

Did you get your GN yet?

Steve
----------
Potomac Forge
W.F. Moran Jr. Museum & Foundation

[D.Ellis]

Originally posted by Steve Nuckels:
Great project Darcy!  I love the sheath & Knife!

Did you get your GN yet?

Steve
----------
Potomac Forge
W.F. Moran Jr. Museum & Foundation

Thanks Steve. No Lil Creep yet........should be any day though. I am almost going nuts!    
Darcy  

[Orion]

      Just excellent.  Congrats.

[Ray Hammond]

Bet you'll be able to skin grizz with that one pilgrim!

   

[William McBride]

A big thank you for all the time and effort that you out into this project. I learn more from this forum than anything