I'm looking for appropriate sheaths that would accommodate Irwin Marathon 2011201 - 15 inch ProTouch Coarse Cut Saws that I'll be donating to a Boy Scout Troop.

Portage Keeper is the resident Irwin sheath master craftsman.

Here's one idea and very easy to make. Get some of those inexpensive colored plastic cutting boards from Target or Wal-Mart. Fold in half on the long side and clamp the top edge together. Now using a hot air gun, wood spacer between the fold (about1/4" thick) and piece of wood to press down at the fold as you heat the edge. Heat and press until the fold is closed down. Not too tight or the saw teeth will grab as they go into the sheath. Now using the paper sheath that comes with the saw trace the outline of the paper sheath onto the plastic. Clamp on both sides of the line to be cut and using a Dremel tool with a cutting blade or fine toothed hack saw blade to cut along the lines to get a copy of the paper sheath (cut heavy to leave room for the pop rivets and top of saw blade). Using pop rivets to close the top edge you have a pretty nice sheath. You can easily attach some nylon webbing and plastic buckles to hold the saw in the sheath.

Similar idea. We made these with plastic gutter material.

Knoozer: "Portage Keeper is the resident Irwin sheath master craftsman."

PK and OS's simple patterns work fine and make an easy project.
But I'd reserve the "sheath master craftsman" for Ragged. Not as simple and not a home,club project but to his credit the best I've used.



butthead

I know the scouts are tougher on stuff than I am these days, but I just use the cardboard it came in with a few upgrades. I ran a piece of duct tape along both sides and then added a ~2" extension to the bottom because the teeth were poking out a bit. I use a bread twist tie through the hole to secure it to the saw. (Pack a few extra for when your scouts lose one).

I'm not super weight conscious when canoe camping, but some of the other sheaths recommended on here weigh as much as the saw. My cheapo, 5-minute fix has survived three rainy October trips and is in great shape.

+1 on Portage Keeper sheaths.

Here’s another idea for the scouts to make their own. It’s pretty simple and a lot of fun to make them out of leather. Just use the cardboard sheath for a template and they can add their own designs with a wood burner.

Great job on the logo Stimpy.

Dicecupmaker on here makes a badass sheath. It's on log in pic.

Dicecup made me one too also one for my hatchet

Those are some sweet looking works of art that Dicecup has made. I bought one of the sheaths that Ragged made several years ago and it is simply amazing, you'll go through a few saws before the sheath would ever show signs of wear.

Made a few of them some years back.

We've gone through quite the progression over the years, each time feeling like we had finally found the PERFECT solution:
Homemade Portable Buck Saw --> Bob Dustrude Quick Buck Saw --> Irwin Coarse Cut Saw with Ragged Sheath --> Silky BIGBOY 2000...
Never did make a stop at any of the simpler Sven Folding Saw models or the Agawa Canyon BOREAL21, but we were tempted at times...