I DEF do not want to have bad CS I am just worried that the average person might think it is plug N play. Would I be smart to wrap my blade in blue tape to make it slightly thicker? Is the retention in the handle or the blade itself?
if they don't fit just offer to make one a little thicker or thinner. you don't
want to have bad customer service. if you warranty your work free of defects that would be a good idea. just keep the right to decide if it is a problem or not.
I typically cover all my blades with tape and go for retension in the handle ricasso area. This is more important with satin finish blades, as they will show scratching.
It seems like you may be jumping in to this kydex business with both feet. I know it can be fun and exciting, so more power to ya. I considered doing the same but feel I'm still learning on my somewhat extensive collection and sheaths for a few buddies.
