Rifle Scabbard Issue

[reuben cogburn]

I'm designing/building a scabbard for a guy. Technically it is for a shotgun.

The issue I'm having is that the charging handle (bolt handle/knob) on the shotgun is an extended enlarged variety.

I want to do something other than just allow more room in the scabbard by making it a big large, but I don't want it to be to complicated to assemble.

Anybody ever encounter a situation like this?

I thought of cutting a long slot in the scabbard, then sewing in a formed piece over the slot. I could use a pice of aluminum etc and sandwich it between two thin pieces, form it, then sew that onto the scabbard, but that is hitting the complicated end. I'd rather explore options as there may be something "easy"...

[Tree Reaper]

Can you leave the bolt handle out of the case or does it have to be enclosed?

[reuben cogburn]

He wants as much enclosed as possible as the scabbard will be lashed to the wing struts of his bush plane (outside!). Describing this is kinda difficult.. I'll try and get some pics up....

This bolt handle isn't like one on a rifle. It is just a knob that sticks out, and it sits far forward of where a bolt on a rifle would. It can be removed, but would be easy to misplace.

If I cut a slot it would be halfway up the side of the scabbard. It would compromise the structural integrity as well....

This shotgun is used as bear protection in Alaska. The pilot doesn't want to have to worry about partially disassembling the gun to put it in the scabbard, or in case he needs the gun quickly!.

I also thought of sewing some type of spacer on the inside that let the handle ride inside a channel.

I'm experimenting with scraps right now. This is going to be an...................... interesting..............project......

Edited June 24, 2013 by reuben cogburn

[Matt S]

The US army ones from the 40s (m1 rifle and carbine) had rivetted on steel channels to getvaround exactly this issue.

[reuben cogburn]

I might have to do a search and take a look at one. I wasn't aware they made one like that. The bolt handle position on the carbine would be in a similar position..

[TomG]

How about wet forming a channel down the scabbard with a square dowel rod.

Tom

[Tree Reaper]

Not to ruin your project but he might be better off with a molded plastic scabbard and let you make a leather harness that would fit the strut.

The plastic jobs are molded for a bolt.

Edited June 24, 2013 by Tree Reaper

[reuben cogburn]

I could definetly just mold a channel, but it wouldn't hold up long. not with the abuse it is going to get. Thats why I figured if I did it that way I'd support it with a bit of light metal. Like a steel lined quickdraw holster....

He wants it in leather.. I'm sure a Kolpin would suffice. He has been using a much modified old leather rifle scabbard but it is pretty much shot. He wants something more custom??.. I guess..... to fit his Benelli riot gun.

I guess I'd rather make the $$$ than walmart..

And I love a good challenge... Or so I keep telling myself!

And, he is a regular customer. This is the first scabbard of this type for me. Other than the bolt handle, it is pretty straight forward. I just want it to look and work properly..

Thanks for the input!!

[Northmount]

You can form Kydex and fit it into your molded design for support. It's light weight and can be glued in with barge contact cement. Rough up the smooth surface with 80 grit sandpaper.

The Kydex might even do for wet molding your leather.

Tom

[Tree Reaper]

I'm not a salesman for Koplin but what about a leather covered Koplin?

The leather could be molded around the case and it would have the support of the plastic to protect it from the foul weather it's going to see.