The scabbard you show is molded using a two part mold. We cnc machine the kydex to get the slots and shape and then mold it. We do this of course to make everything consistent. The scabbard in question is completely ambidextrous, MOLLE carries 6 different ways, weapon sling carries and belt carries. We use 0.125 thickness to ensure nobody gets poked accidentally...
To make one for a hawk you have on hand, I would take a piece of oversized kydex, fold it in half and then mold it around your hawk using PVC foam and some thick boards or metal plates. (a normal kydex press would work fine - our press uses thick steel plates and 2" thick pvc foam) That is the easy part. Next you'll want to trim the outside perimeter to shape - generally speaking with a belt sander. You'll want to leave a little material around the bottom to make a lip or what I call a ramp. Once it's profiled take a heat gun and start working this lip out so that the hawk has somewhere to go and ramp into the scabbard. The best shape looks a little obscene - a good guide for getting it right.
Then drill your holes - that is easy. Once you have holes drilled you can use those to bolt it down and make slots if you want slots. (milling machine works well) A leather workers slot punch will work in a pinch but is best to use this hot. You'll at least want slots for the retention strap if you are going that route, the other slots are not necessary for the average guy, especially if you are not going sling or MOLLE.
Throw your eyelets in and set them and you are good to go. Knifekits makes great eyelet setter dies for this.
You can make scabbards as simple or as complicated as you want...the scabbard you pictured took us a little over 3 months to develop from start to finish.
Good luck with it! If you have any questions just ask...I'll keep an eye on the post.
Ryan Johnson
RMJ Tactical
