Again, I want to make it clear this is just my attempt at making something. The idea as far as I know belongs to Adam Savage.
Step 1: Try to Plan It Out
I decided to try using a piece of cardboard to map out the shape of my sheath. I happened to have a piece of thin cardboard available, similar to cardboard from a shoe box in thickness, which worked nicely as it was relatively the same thicknesses as the aluminum I was going to use.
So I traced out the wave on cardboard and simply used the tool itself as a guide for the inside width and the thickness of the sheath. The first picture represents my first attempt at this. Then I folded the cardboard at all the creases and just tried to put the wave in. My first attempt was not very successful.
After realizing that my dimensions were all a bit small, I used that pattern to help me draw a slightly larger model on a new piece of cardboard. After folding this I realized that the knife fit almost perfectly. It was just snug enough that it could hold the knife in place.
With the second attempt a success, I used it's measurements as a guide to help me draw up a plan. Once drawn, I used that plan to draw out a scale pattern on a piece of paper. I again folded the paper to make sure the knife still fit well and it did.
So after lots of thinking, and a bit of prototyping I was able to come up with a fairly decent model of what I planned to make from aluminum.
Step 2: Use Your Plans!
By the way, I am using a piece of aluminum I bought from McMaster. Here is the description :Multipurpose 6061 Aluminum, Brushed Finish, 0.050" Thick, 6" X 6". I downloaded there app and ordered it that way. I believe it was about $7 for the aluminum and $7 for shipping.
So, I put the paper pattern on the aluminum and just traced it with a pencil. After tracing I took and cut out the outside shape using my jigsaw with a metal blade. I also used a small file to clean up the edges a little.
Step 3: Bending
Since I've never bent metal before in my life (at least not on purpose) I wasn't sure what to expect. Since I had a bit of scrap aluminum after my cuts I decided to test my Bending. I marked a straight line and clamped the aluminum in the vice at the mark I made. I then used a hammer to lightly tap the aluminum into a fold. My first attempt, I hammered to close to the bend and tore the metal a bit. So I tried again tapping about a half an inch farther away from the crease and had much better results.
Having an idea of how to get the aluminum to bend I decided to start Bending my sheath! I ran into all sorts of trouble with this. I realized the jaws on my bench vice were really thick so I couldn't bend the small edges first. So I decided to do the big bends first. I bent one side over, the slid the knife in to see if my marks were right. And actually, very similar to Adam, I found if I bent the metal at my marks I would have made it too big for the knife.
I wish I had taken better pictures of this part, but alas I did not. I had to set the metal in the vice prepared to be bent and I slid the knife in between the vice and the other bent side. All this to try and get a feel for the size of the knife and the sheath. Sorry for not having a decent explanation of this.
I did make the second bend though, but I couldn't get it bent to a 90° angle, again because the vice was rather large. So I cut a piece of wood to slide into the sheath so that I could hammer the side to close the gap without destroying what I had done so far.
Luckily, the knife fit!
Step 4: More Bending
Step 5: Belt Loop
Now, I don't have a rivet gun... Or rivets... Or even leather. I also don't trust myself not to ruin my only piece of aluminum that I have already been lucky enough to have bent correctly the first time. So I decided to try and make a loop from the extra aluminum I had from my cutting to make a belt loop from.
So I first measured out the loop, and cut out a piece with my jigsaw. And then I made my first two bends. I soon realized though that my loop would not be big enough for my belt. So I tried to bend the aluminum back and actually broke it right at my bend. Now realizing that I need to be careful and to make the bends bigger, I worked carefully on what was left of my piece.
Step 6: Attach the Loop
Step 7: Finishing
I proudly wore it to work!
Step 8: Done!
I want to thank Adam Savage for his great idea! Check him out on Tested. Com where you can watch him make some incredible things!
So here is my first instructable, it's a bit strange since this wasn't my idea. But I was really excited about the process. I was really excited about making something new, something that would house my new favorite pocket tool my Leatherman wave! Since I was so excited, I wanted to try and share my experience. I hope this is helpful,thanks for reading!