Replacing the Velcro with Snaps On a Nylon Sheath

[turnsouth]

A little over a week ago I started to EDC the Leatherman Core, and before I settle down on what sheath to carry it in,  I wanted to give them all a try. The first one I've been using is the standard nylon “pancake” sheath, which I found very good except for the massive amount of Velcro  (you can see the post here with my thoughts.)

So I decided to try and replace the Velcro with snaps. I was able to get it done, trying different techniques, and got it down to a list of steps anyone could take to do the same mod.

• 1. Wear the sheath, as is, with the tool in it for a week or more. When the sheath comes new it is stiff and flat, and it takes some time to get it “broken in”. The main reason for this is that even though you could put snaps on it from new, it may loosen up after some use, and you would end up with the tool being loose in the sheath, or the closure flap wrinkled.
  
  
• 2. Next pick the place you would want the snap(s). I chose to put 2 snaps for two reasons, first the wide with of the Core sheath, and second to make the closure more secure. Also with two snaps, I didn't have to use super heavy duty ones, with such a strong snap springs, that it takes a pry-bar to open them. As you can see in the photos the “Leatherman” logo is sown crooked onto the sheath I used, so I could not use it for a guide to make the snaps symmetrical.  Mostly this is just aesthetics, the important thing is to make sure that the snaps hold the flap down the way you want.
  
  
• 3. With the tool in the sheath, use the receiving end of one of the snap halves (the half with a hole in it) as a guide to make your hole.
  
  
• 4. You will want to use a sharp drill bit, about half the size of the snap stud, for this step. With the tool still in the sheath, and the Velcro firmly secure where you want the flap, carefully drill through both layers of the nylon in the center of the snap (I just turned the bit by hand. A sharp bit goes through the nylon easily). In order to make sure that I did not scratch the tool, I used black high carbon drill bits (the kind for soft wood), but if you are worried about scratches, or if your tool / knife is susceptible to scratches, I would recommend using a small block of wood, or something similar that would be a place holder for the tool. The important thing is to make sure it is the same size as the tool, so that the sheath keeps the same shape as with the tool in it.
  
  
• 5. After you have your “pilot” holes you can remove the tool, and trim the Velcro. Take a single edge razor blade and start by shaving the loop part of the Velcro off (the fuzzy part). You want to get it all off of the Velcro backing, for a neater appearance, and to make sure that your snap sets flat against the backing. After the loop side is done do the same for the hook side. The hooks are hard plastic so be careful with the blade, it takes some effort. If you want to save time a big help is an old electric razor. After you have most of the Velcro trimmed down, the electric razor cleans up the rest quite nicely.
  
  
• 6. At this point, with all of the Velcro gone, you should be able to see your pilot holes. Take a drill bit just slightly larger than the snap stud (the part that will push through the Velcro) and enlarge the holes to that size. Don't worry about a perfect hole, that is covered in the next step.
  
  
• 7. Now take the snap with the stud and push it through the hole. Using needle nose pliers to hold it take your single edge razor and trim off the little pieces of nylon sticking up that the drill bit did not cut off. Do this in all places where studs pass thorough nylon. Again the goal is a nice clean hole for good snap setting.
  
  
• 8. At this point all that is left is to set (rivet) your snaps. Male on the sheath, female on the flap so that the finish piece of the snap shows when it's closed. I used a snap setter with one of those little anvils custom fit for the snaps. You could use a bench mount unit, but it's easier to get the little anvil into the sheath for the male end.

Enjoy!

[DaveK]

Nice work turnsouth

[max6166]

Great write up! 

I want to do the same thing to small pouch I have. Where did you get your snaps from?

[jzmtl]

Great write up! 

I want to do the same thing to small pouch I have. Where did you get your snaps from?

Walmart together with sewing supplies, comes with setting tool, I got some and swapped some velcro with it.

[RaptorMan]

Thanks for putting this together. I have a sheath I have been working on and wanted to go with snaps instead of velcro.

Thanks again for the write up.

[Neil]

Nice write up, thanks

[MultiMat]

That looks good mate , I have wondered about this mod 

[turnsouth]

Great write up! 

I want to do the same thing to small pouch I have. Where did you get your snaps from?

Like jzmtl said Walmart has some, but a lot of the newer Walmarts are reducing their sewing notions departments, so it's hit-and-miss.

Any large fabric store will have a good selection. Joann Fabrics is coast to coast in the US. They're kind of the Walmart of fabrics, and supplies.

A really good source is either a local tailor, or tack shop that does custom work. While they might not have a large selection in stock, they will have peddlers, and suppliers stopping by every week. It's a really good way to get specific items, without having to order a hundred of something on the internet.

Finally, you can usually get them at any local craft shop that handles leather and canvas supplies.

turnsouth

[turnsouth]

Thanks everyone for the positive comments. 

[Anthony]

I prefer snaps over velcro myself, great writeup/tutorial