Just finished my first pair of sayas for a couple of kitchen knives I made, and I'm second-guessing the fit. I carved them out of some ebony offcuts, chisel and a lot of sandpaper wrapped around a dowel. One of them holds the blade nice and snug, the other one the knife just slides straight in and rattles around a bit if I shake it. Is that normal for a first attempt or did I mess up the mortise? I was going to try shimming the inside with a thin sliver of wood glued in and re-sanded, but I don't want to split the walls since ebony is allready pretty thin where I carved it out.
Also curious about the retaining pin. I drilled through both walls and pressed a brass pin in, but it barely holds the blade in place. It feels more decorative than functional right now. Should the pin actually be doing the locking, or is the fit of the sheath itself supposed to do most of the work? Not sure if I should epoxy the pin or leave it friction fit so I can pull it out and rework things later.