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I purchased a “Standard Leather Sheath I” for my Leatherman Kick, the black oxide version that came with a nylon sheath that I don’t think is discrete enough for EDC.

The leather sheath is fine, but the sheath is slightly larger than the Kick itself so it rattles when you walk around. So I came up with the idea of making an insert so the Kick would fit snuggly into to the sheath.

Please notice that measurements provided are in centimeters only.

Materials needed:
Knife or scissors
A sheet of plastic, e.g. a DVD-cover
Self adhesive Velcro or duct tape
Masking tape (optional)
Lighter (optional)


Step 1: Prepare the Plastic Sheet

Prepare a sheet of plastic measuring 6 by 9 cm. I got my sheet of plastic from a DVD-cover.

Apply masking tape and draw lines according to the photo.

Step 2: Cut the Plastic Sheet

Cut the pieces of plastic.

Step 3: Apply Velcro or Duct Tape

Apply Velcro or duct tape.

The Velcro keeps the insert in the sheath when you pull the knife out. I guess the rubbery surface on duct tape will have the same effect.

If you haven’t got any self adhesive Velcro, you probably will be able to use ordinary Velcro and a hot glue gun.

At this point I used the lighter to round the edges of the plastic piece measuring 3 by 9 cm.

Step 4: Put the Insert Into the Sheath

Insert “the creation” into the sheath, wrapping it around the knife will make it easier.
I have a multi-tool and sheath that I wear all the time it started to develop a hole in the bottom where the tip rests and was advised to try gluing a piece of leather inside like from an old leather belt. I never did glue it in but it has been in there for far longer than I had it before it developed the hole. <br>uncle frogy
Nice. I've seen the same issue with extra room in these sheaths, but I usually find a ferrocerium rod of the right diameter to take up the slack.
super cool!

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