With the knife being custom made, there would be slight variations I'm assuming... Would that affect the effectiveness of the sheath made off the template?
Maybe there would be slight variations if it were anyone else making the knives. Steve is a blacksmith with over 35 years of experience, 30 of it as an armorer for many Hollywood productions.
Add to that, its the exact same method we used for the movie...Steve made the prototype which he shipped to me. I made the patterns for the sheath based on the prototype then shipped the prototype and first sheath to the Studio for approval.
When they gave the green light to make the rest, Steve worked off HIS patterns, and I worked off MY patterns. The studio was ecstatic with the production pieces.
I wouldn't sweat it.