Tuf Cloth is great stuff - I just wipe my blades down w/ it, let it dry, and store them in the sheaths. My 1095/5160/SR77 blades haven't shown a hint of rust.

Make sure and let us know how your sheaths turned out!

I have a kydex sheath on my DM and it did cut at the ResC a little - I just heated up the handle a little tiny bit and molded it to fit better. I'm sure the same can be done to the mouth of the sheath though.

Ask Leatherface or Rainwalker or Jeepsrock.

And, Welcome to the Yard!