Making a tooled leather pocketknife pancake sheath. If you own an oldfashioned pocketknife that lacks a pocket clip like most modernday pocketknives have, and you’re not fond of it laying at the bottom of your pocket bumping into everything else, then this may be the leather project for you. Made from a minimal amount of natural vegetable tanned leather, this is a great inexpensive beginner project that can be a blank canvas for creating your own unique design with dye colors and tooling patterns. If you want to learn how to layout a pattern for your specific size pocketknife, I recommend checking out this video from saddle maker Don Gonzales:
   • How to Make a Pattern for a Pancake K...  . He shows his process of laying out and designing a pancake style sheath pattern for any size pocketknife. For my sheath I decided to try an intricate diamond tooling pattern on the front side and a simple border and cross on the back side. But if you want to go with a simpler looking sheath, you can always skip the tooling altogether for a cleaner aesthetic. As far as the color of my sheath, I wanted the sheath to have a ventage look, so instead of applying the dye fade using my airbrush (which gives a consistent looking fade), I applied the dye using a fade technique I learned from leathercraft master Freddie Matara.   / freddie.matara.leather  . This process involves applying dye using a small piece of compact cloth and rubbing the dye into the leather using small circular motions while allowing some overlap of different color shades to create the fade. After applying the dye in this fashion and after adding some antique paste, the result is a very antique rustic look that makes a new project look well worn and vintage. The sheath is handstitched together using beige colored Tiger Thread which really pops with high contrast against the darker tones of the sheath. I hope you enjoy this leather sheath project video and try making one for yourself.

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MATERIALS
Leather:
1.5mm thick natural vegetable tanned leather
Tooling:
Scotch Packing Tape (To prevent stretch)
Finishing:
Fiebing’s Pro Dye, Light Brown (Cut 5/1 with 91% Alcohol)
Fiebing’s Pro Dye, Dark Brown
Fiebing’s Pro Dye, Chocolate
Fiebing’s Antique Paste, Medium Brown
RTC Sheridan Resist & Finish (Finish top coat)
Wool Dauber
Pieces of Cut Tshirt material
Cotton Swabs
Paper Towels
Cotton Circle Pads
Burnishing:
Tokonole
Gluing
EcoWeld Contact Adhesive
Stitching:
Thread, 0.6mm Ritza Tiger Thread, Beige

TOOLS:
Pattern / Marking
1/4” plywood pattern with marks for pouch area width.
11/2” (38mm) wide wooden spacer (To mark knife pouch area)
4mm Wooden Spacer (To mark tooling guide lines)
Ink Pen
Scratch Awl
Wing Dividers
Cutting:
XActo knife
Tooling:
Foam Brush (To apply water)
1.6 lb Barry King round maul
S723 Diamond Stamp
F933 Border Stamp
Makers Mark Stamp
Craftool SnapIn Cross Stamp
Finshing:
Medicine dropper
Spring Clamp (To hold cloth for applying dye)
Beveling/Sanding:
Odwen #0 Edge Beveler
Weaver #1 Edge Beveler
Craftool Drum Sanding/Burnishing Machine
Assembly
C.S. Osborne No. 66 Leather Working Hammer (To tamp down glued pieces)
Burnishing:
Needle bottle (To apply Tokonole)
20mm Plastic Applicator (To apply Tokonole)
Round Wooden Slicker
Flat Wooden Slicker
Belt Slots:
13/4” (44.4mm) C.S. Osborne Oblong Punch
Soft Face Mallet
Stitching:
4mm KSBladePunch Diamond Pricking Irons
3” (75mm) Needles
5oz Tack Hammer (For tamping down stitches)

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