> This is completely NON period, but I would take a piece of pvc and put
> it in the pouch. This way, even if he sits on it, it would be protected.
> Completely covered inside and out, it wouldn't even be that
> noticeable.

My first thought was of some of the scabbards in the Museum of London book,
_Knives and scabbards_.  They are (if memory serves) hardened leather tube-ish
cases.  It wouldn't be too hard to make a leather case hardened (over
appropriately-sized PVC, perhaps) in boiling water or hot wax.  Ask the
armourers in your vicinity.  The result might not be what was done in period,
but would at least use period techniques and materials and produce a result that
looks right.

Emma
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