I said I would try to explain how I make my fittings for the sheaths. Here is a couple of pictures explaining the method. I am sorry for the quality, they were taken with a cellphone.
First, the chape:
1, I start out with a paper template and sketch out the rough shape of the chape on the leather sheath.
2, Then I put the paper template on a brass plate and transfer the shape.
3, I use different tools to make all the stamped patterns.
4, To make the rough cut I use a small chisel and carefully strike down on a piece of old railroad track.
5, This is how the piece looks after the rough cut.
6, To cut the outer shape I use a hand held pair of straight-cutting snips.
7, After this it´s time to bend the chape around a metal pipe to give it it´s shape.
8, Then it´s time to get going with sandpaper, files and some elbow grease to smooth all the edges and get rid of burrs. This will take some time.
9, The final stage is to give the chape a high gloss polish.
10, And the final fitting on the leather sheath riveted in place. The leather will be cut after to insure a perfect fit.
I hope this is helpful! I also have some pictures of how to make the smaller fittings if you are interested!