eLuSiVeMiTe
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2 pieces of hardwood. Rout out the knife footprint both sides and glue/pin together. If there's enough meat on the wood you can do something interesting to the sheaf externally. Could make it full size and cut it at the 3/4 mark as a top to encase completely slid over the handle side.If I go for the tube design, assuming I can find some tube the correct diameter etc etc etc, I’ll cut out a piece of dense foam and stick it in the bottom to protect the pointy edge.
An alternative is to mill a slot of the correct thickness into some hard wood I’ve got to make a sort of a cap.
Haven’t quite figured out case yet, so open to all ideas