Make Your Own D-I-R Knife & Sheath
by David M. Dalton

Lurking beneath the psyche of any REAL diver is a deep desire to make his or her own dive gear. This probably explains why every diver ALWAYS keeps a roll of duct tape handy, since as everyone knows, one can make or fix almost anything with a roll of duct tape. In fact less than a month ago I discovered that you could even patch a torn neck seal with duct tape and it will hold quite well (at least for two days, after which even I sent the suit in for repair).

Unfortunately there isn't much one can make anymore. However, there is one thing, the D-I-R Knife & Sheath. Strangely, there is still nothing on the market that meets the specifications for a line cutter (knife) as specified by George Irvine. In fact the design you see here is identical to what he shows in Doing-It Right II. Come on, don't groan, it's about time you hung up that dive knife, large enough to be used by Mel Gibson as his sword in Braveheart, and start using something that serves the purpose that a knife is supposed to serve, that is being a line cutter. It is simple to make and very inexpensive (it is approximately $12 for knife and sheath).

First go to your local "fine cutlery store", also known as the grocery store and look for the Betty Crocker "Steak Knife". Be sure it has the "Betty Crocker D-I-R" seal of approval. It is SS so it won't rust, serrated so you won't have to sharpen it, and it is cheap enough at $4.99 than you can get a new one every several years. For you real skinflints, they do put them on sale from time to time and I got mine for $2.99!

Click photos for a larger view

Next put the knife in a vise with the handle down and all but the first 1 & ½ - 2 inches sticking up out of the vise. Whack the exposed portion of the blade with a hammer and break it off leaving a short, stubby, blunt blade. Then round over the tip with a grinding wheels, a belt sander or whatever, so it is not sharp.

Next take a piece of 2" webbing from an old weight belt or harness and cut a piece 18 ½" long. Fold it 6 ¾" from the end and then 6 ¾" from the first fold in sort of a " Z " shape. This will leave an end that is about 5" long. Then go the shoe repair shop and have them first sew the 5" flap to the part it is folded against to form a pocket. They should stitch down one edge across the bottom and up the other edge. Then fold the back flap down to form the loop and have the cobbler (that's "shoe-repair person" for you youngsters) sew the flap down the edge across the bottom and up the other edge. Take a piece of webbing with you to show them how big the loop has to be and explain what it is so they understand and don't sew it shut. I was charged $6.50 for this service.

That does it. You are done. $4.99 for the knife and $6.50 for the sewing brings it just under $12. I assume that you can scrounge up a piece of webbing for free, if not, that will set you back another $2. You can't beat that, AND it's
D-I-R!