The sheath was the worst part of this costume, trust me... I hated it so much xD

First I took two pieces of Worbla, which were slightly bigger than the sword itself. Then I glued black velvet to the inner sides, so the sword wouldn't take damage from scrapping.

Afterwards I heated the Worbla just a little bit and pushed both pieces on one side together. Now I had to heat the other sides and form little edges, so I could hotglue them together. Dents got evened out by applying Worbla Deco Art. That's it.

It's hard to to with just one layer of Worbla, because I constantly had to worry about dents. The material gets really soft when heated to much and tends to loosing every desired form^^