The best scabbard building site I have ever seen...

[Mirimaran]

http://yeoldegaffers.com/project_scabbard.asp

Awesome, with pics, and complete with belt lacing how-to. Can't wait to try this out!

[Peter Remling]

He's a regular on SBG SwordBuyer'sGuide and they have a lot of great how tos on grip wraps etc.

http://sbgswordforum.proboards.com/index.cgi?

Some excellent reviews on moderate priced blades.

[Greg]

Those how-tos make me happy. Dag nabbit, I have too many projects to be working on to start another one. Thank god I don't have any blades without scabbards right now, or I'd be off to the hardware store already...

[Beornmann]

Truly a great bit of instructions and what a help it will be. Thanks!

[Brendan Olszowy]

Yeah it's a cool tutorial, and a great website - love his shield press.
Re the scabbards; I like the three layer 'easy' method for simplicity and foolproofiness. I'd just use a single centre layer and jigsaw the sword profile out of it. And for the top and bottom I'd suggest 1/8" if it's available, as all that extra thickness is unnecessary and a slim scabbard looks the goods.
You can also line the cavity with felt to help snug up the fit and stop rattling.

If you're in US and have access to slats of poplar from your home depot consider yourselves very fortunate. Here in Australia we don't have it, and the closest choices are plywood or balsa. hmmm.

If you're looking for affordable Chapes and other fittings here's a cool page of links for them:
http://sbgswordforum.proboards.com/inde ... read=14090

[Peter Remling]

I use 1/2" plywood for my middle piece and paneling for the outside pieces. For lining I use sherpa or synthetic wool. Once the sword is oiled and sheathed the synthetic wool acts like raw wool as far as coating the blade. As a synthetic it doesn't absorb the oil so the oil remains on the surface up against the blade.

Here's a link to the system I posted a good while back;

http://ranger.budgetauthenticity.org/fo ... p?f=5&t=76

I've been doing these for over 20 years and the first were a good deal thicker as I was useing 1/2" pkywood for the middle and 1/4" plywood for the outside until I thought of paneling about 14 years ago and I've been useing it ever since. Done over 100 scabbards for swords, knives and daggers.

[Willrett]

I will be making one for each of my 2 cold steel saxes, as soon as I get some material and alittle more time.