Hi Richard,
well done scabbard looks ace
I assume you traced the outline of the blade on two planks of wood, chiselled the 'depressions' to accept the blade, cut the scabbard halves from the plank. Joined the halves (temporary ?) to check blade fitted, once OK . Joined the halves and 'finished' the external surfaces. Any additional info would be appreciated as I have several 'scabbardless' swords I would like to sheath.
As to scabbard 'coverings' if you are going to use a cloth....I think I am right in saying that a cotton/canvas backing should be between the covering material and wood.