Just thought I would share my experience with the magic product.I made up the mold out of 6mmm (1/4 inch) MDF board this is easy to work but the dust is a worry for me. So its on with a cheap disposable mask and set up the little fan in the work shop. This way I stop sneezing and look a lot better.
I made the blade part of the mold; call that the male. and made the female part apx 6mm bigger allround. So when the two parts sat together there was apx a 6mm gap between them all round.
G clamped a heavy board to the kitchen bench as a base.
Taped the female part of the mold to this and drew straight precise lines out from the mold similar to a hash mark.
I taped the male part of the mold to another heavy piece of board and carefully located the two pieces of the mold together.
By dint of some careful guestamation satisfied myself that the line up was ok.
Projected the earlier lines from the base wood onto the upper wood. Now I had a key to remove and re-locate the the two pieces of the mold together accurately.
Cut out your Kydex and leave plenty of margin around the edges. It easy to remove later but you cant put it back!
Turn the kitchen oven on to the required tempreture and ensure exhaust fans are going and windows, doors are open cause Kydex pongs when it gets hot.
Place the Kydex onto an upside down oven tray. Upside down as you want ot be able to slip the piece off the tray when it is hot enough.
Heat it up. Open your mold by having the upper immediately in position so all you have to do is lay it down in one movement to correctly locate the two parts of the mold together. Strongly recommend you do acouple of dry runs.
Using heat protection remove the tray and tip the Kydex onto the lower mold board and immediately place the upper part into place then throw your weight onto the upper to press the whole shebang together.
My first attempt was a success and I have made a few since.
Just have all doors and windows open and the oven promptly turned off and left open to ventilate. The cook need have no worries as I have not found any odour ever left in the oven after doing a Kydex sheath.
The dimensions will have to be worked around the dimensions of your particular blade and the dimension too of the knife guard.
Kydex is very forgiving stuff cause if you stuff up an attempt or two it can be reheated and start again. Dont be hard on your self as we used to say in the Sheet Metal trade the bloke (guy) who has never made a stuff has never made anything.