Remember back in May when I wrote on how to make a scabbard? Recently while making the sheath for a factory-sharpened knife I discovered that the instructions I gave for the all-leather, side-seamed sheath back then are only fine as they are if your weapon is unsharpened.
Otherwise, you need to include a welt, which is a strip of leather glued around the inside of the sheath between anywhere a sharp edge and seam might touch. This will prevent the blade slicing through the stitching. It also, as a bonus, gives the sheath a less flat shape.
Instructions can be found all over the Web; as an example, see steps 4 and 13 here.
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