" Have you considered sewing the entire sheath? I, for one, really like visible thread"
Showing off my ignorance here I'm not sure I know what you mean? Could you explain or post a pic of something? I'm always willing to learn something!
I use screw back conchos on many of my sheaths. I use 8-10 oz. veg tanned leather for all sheath work. When attaching the conchos I take the concho to my belt sander and shorten the screw protrusion so it does not go past the leather thickness. I shorten the screw a little also. I put a drop of thread locker on the screw before putting it in (so the concho will never work loose and fall off). After screwing tight I use shears and cut a little circle out of some thinner veg leather and contact cement that over the screw. I use the rounded end of a tool handle to press the patch down hard all around to set the glue well. I shudder to think of a screw scratching one of my blades. Works for me.
I did consider using copper rivets at one point in time. Actually made a couple of sheaths with them and just did not like the looks really. I use a heavy welt inside to protect the threads from being cut and to date they seem to protect the thread very well (and these knives are scary sharp too). I used to have a web site but let it go. It was not generating any sales and I decided to save $120 a year cost.
I have used several different patterns for sheaths and keep coming back to the curvy pointy style. I guess I just like the design really. To date I haven't had any complaints about the corners wearing. I think the look just screams custom design (but then what the heck do I know?).
I managed to stumble across this site the other day and registered. Hopefully you folks will answer questions I have about my leather working. I make custom knives and work primarily in damascus steel. I started making my own sheaths since being able to claim sole authorship of an item is important to me. I will put up a couple of pics of some of my recent work. Let me know what you think folks!