Outline - A Rapier Scabbard with a Catch

First of all: BE CAREFUL

Supplies

1. PVC or similar pipe with ¾ inch internal diameter (may need to be wider depending on your sword)

2. Leather

• 4 mm

• 0.8 mm (or fabric of choice)

3. Artificial sinew

4. Preferred dye or paint

5. Leather seal

6. Acrylic seal

7. Metal sheet (18 gauge -20 gauge is probably best) – recommend brass or aluminum

8. Two-part epoxy

Measurement you’ll need

1. Length of the blade from the base to the tip (including cap).

2. Width of the tip at its widest point.

3. Width of the blade at its widest point (if different that the tip).

Steps

• Cut your pipe about 1 to 1.5 inches shorter than your blade. The cap should extend clearly past the end of the pipe when placed inside.

• Make a Mitre Cap.

  • Cut a patch of 4 mm leather with an internal diameter matching the width of the sword’s cap. It should be between 2.5 and 3 inches long.

  • Punch holes along the edges that will be the internal seem.

  • Sew the leather into a tube with an internal diameter to accommodate the rapier cap (wetting the leather can help with the shaping).

  • Cut the end of the cap into a taper, and wet to form a point

• Drill holes along the end of the PVC and the Mitre Cap.

• Sew the cap into the pipe using artificial sinew (take it in stages).

• Apply epoxy over the threads and to hold on the cap.

• Apply raisers (if desired).

• Cut out cover leather (0.8 mm) and sew over the core (dimensions - core circumference by length). If you use fabric instead, use the same process.

• Dye the leather (and paint if desired).

• Seal the leather (first leather seal, then acrylic seal).

• Make a chape out of sheet metal and epoxy/glue onto the end of the scabbard.