Made some big updates/additions to my Jorah gear recently. Here's what I did.
First, I rebuilt the sword scabbard since the original version used some vinyl and sticky glue and generally did not look/feel all that great.
I've build scabbards from birch plywood. The top/bottom is 3mm (I believe) and the core is the thickness of the blade of the sword. I'll sand the blade down a bit to get a nice snug fit.
Here's the glue-up. Next, I'll round over the edges with a router and sand everything down smoothly.
The throat of the scabbard. I finished it with just black spray paint and spray lacquer. I've found I can get a really nice finish with that if I'm not doing a leather wrap.
I sprayed the lacquer on over the feathers to adhere them to the scabbard.
The chape is made from epoxy putty, painted with metallic paint then coated with black and scratched off in a few places to show wear and tear. I also made a dirk and scabbard using the same techniques. There's a separate thread on that somewhere around in my history too.
This scabbard is much more streamlined and just feels much better than the old one. Glad I remade it.