Kydex, my new hobby (pic heavy and long-winded)

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Jan 20, 2012
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I decided I would try my luck at making some kydex sheaths for my blades (last November:D) I scrounged up enough money from birthday money and an Amazon gift card to get some materials and a few tools I would need---I tried using a toaster oven I bought at goodwill but it didnt have a temperature setting it on and the thermostat on it must have been broken because it never shut itself off.....so I melted the kydex and the thing almost caught on fire----The house stunk like melted plastic for a few days ---I then tried the oven and over heated the kydex yet again---it didnt stink so bad this time but still pretty bad---so the wife put an end to my indoor sheath making--I picked up a heat gun and tried to make some in the garage---it was way too cold--I couldnt heat the kydex up enough to get a good mold without over heating it---the cold would make it set up before I got it in the press----so I had to put my efforts on hold before I ruined my whole batch---I was pretty discouraged by this time--I tried again a few weeks ago and was pleasantly surprised that I didnt completely suck at it. I have made a total of 3.5 sheaths (you'll understand later)--I think they are getting better but I am still learning-I think the most difficult part is trying to find that happy medium of retention-somewhere between having it fall out when you turn it upside down and having to put the sheath between your boots and pulling with 2 hands to get it to release:D-I still am trying to figure out a decent belt carry system-thats where I think the true artistry comes in (azwelke, 710 and godspeed....I dont know how you do it)--I welcome any and all comments...especially from all you amazing kydex benders on BFC. (Take it easy on me;))--As far as my leather working skills go.....I have none, so please no comments on that:D

Sheath #1---I made this for a friend's Gerber Prodigy---I used my own Prodigy to make it but then traded before I took a pic of it with the sheath (duh)---The flair from the bolster/guard made it difficult to put on a belt attachment that made the knife stay vertical on the belt--I ended up making some sort of angled clip, then attached some leather to it----very very crude but functional---
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Sheath #2--I made this for another friends Mora Robust--I think this turned out a little better--he didnt want a belt attachment--so I spaced the rivets to fit a tek-lok----I want one of those thicker Moras--I love the way it feels and cuts.
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Sheath #3--I recently picked up a Nessmuk from Larson Forge and Finish--it came naked---My dad saw it and loved it--I figured since he only has one fixed blade and has been using it for 40 years, (and I wanted it to put in my collection---its an old school made in usa Schrade that belonged to my deceased uncle) I would gift this one to him and get another one eventually (I would have given him my bk16 but he liked the nessmuk style blade more for skinning---hes not into camping or anything..just hunting)--I couldnt give him a naked knife so I made some pants for it---I put a leather belt attachment on it---still crude but not as crude---it probably wont get much better---I dont have the patience for leather---
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OBLIGATORY BECKER CONTENT (and how the 1/2 sheath comes in)

I was given a kydex sheath by yet another friend (forum friends are the only friends I have)--He no longer had the knife it was made for and couldnt remember which one it was anyway so he gave it to me--He was pretty sure, though, that it was made by Gavko---I took one look at it and knew exactly what I wanted to do with it---with a little heat and pressure it fit my 16 perfectly---thats why I only count it as half made by me---thanks GAV--
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I will eventually get around to doing some for my own knives-after I finish sheaths for a friend's new BK10 and Buck Paklite (same friend as the Mora owner), I will do one for my 14 and for my 9 when I get more kydex---I like the leather pants on my 2 so I will leave that one alone for now--Thanks for taking a minute to hear about my new venture.
 
Thank you for the kind words.
They look nice and functional.
Practice makes perfect! With practice you will learn your equipment, Which will help out a lot.
Al
 
Keep at it! That's all I did. Pretty soon you'll have people hounding you for a sheath.
 
Those look good, better than my first attempts :thumbup:.

A toaster oven is, IMO, the best way to heat kydex since it does it evenly. Just watch it carefully and every now and then (Every few seconds after it's no longer rigid) take it out and see if it's workable. With kydex there seems to be a split second where it goes from being normally softened to shiny and over heated...Just my 2 cents.
 
JV3 posted up a how-to thread on the ESEE forums a couple months back I believe in the DIY section, and it detailed his process very well.

Are you using kydex or boltatron? Boltatron curls, kydex shrinks, so it does make a difference which you use. For my efforts, I have made my sheaths using boltatron and had some pretty decent success, but there are a few things you need to do to ensure a good form, as well as good retention (but still easily removable).

Start here, I think this video covers a lot of the different aspects fairly well: http://www.youtube.com/watch?v=wntntfsrfEQ

Temperature is perhaps the most critical aspect of good form (IMO), and also too consider how much material to keep behind the handle flare. I think too many kydex sheath makers have too much material sticking up past the point they need to. Again though, just my personal opinion. Good luck, it looks like so far you are getting the idea down pretty quickly!
 
Looks great man! The only kydex 'work' I've ever done is re-heating old sheaths/holsters to fit different models. Keep up the good work!
 
Looks good bro wish I had the time and patience to do this kinda work!! I'd love to get a kydex for for one of my non bkt knives!!! :)
 
Sheaths look sick. I like the heads up on the wife not allowing it in the house. Probably saved me there, lord knows that happens enough. What ended up working for you the last time that did the trick. I haven't dabbled into making sheaths yet, but from what I can see, kydex is the way to go.
 
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