A bit tardy, but here's what I did.
Cut the sheath, glued the gusset, wet formed the 6 oz. leather interior over a curve, glued the cut out Stingray hide over the slightly pre-formed interior. Drilled/stitched/glued the belt loop and the rest of the holster, stitched all around, starting at the top opening. Sanded/slicked the edges, wet moulded the sheath to the knife. Finished the edges. Not as tight as a single piece of leather, but plenty secure.
If/when I do it again, I will use more glue; it is flexible, and after curing, allows water forming really well. I now have a beautiful, durable sheath, and a handsome knife.
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