you came out with a fantastic sheath! what process did you go through to make it?
Thanks man. I'll try to include as much as I can
Supplies (ordered all from knifekits.com
Kydex (.08 thickness)
Rivets 8-8
Chicago Screws 1/4 inch
"Mega" heat foam (for the press)
Pinch Fastener
Rivet punch
-You'll also want a power drill with a 1/4 drill bit to make the holes for the rivets. The wood I used to make the press was just an 8 ft long 10 by 1, from home depot.
I ordered a 24 inch by 12 inch sheet of kydex, heated it in the oven on 250 degrees for about 10 minutes. When it was very pliable I lay the sheet into the press I made. Then I placed the kukri on the kydex, and folded the kydex over the kukri. I then closed the press onto the kukri and stood on the press for about 10 minutes. By this time the kydex had almost cooled completely.
After that I used a ruler to make an outline of where I'd want to cut the kydex around the shape of the blade. I spaced drill hole marks 1 and a half inches apart except for the two toward the blade tip. I picked up a cheap dremel with a bendable attachment for the trimming from harbor freight (I would highly recommend using this method for the trimming and smoothing. Well worth the $25.) After the holes were drilled i simply used the rivet punch and a hammer to flatten the rivets into the wholes. Then I used the dremel to finish trimming the edges.
For the strap I looked for nylon strip (which are harder to find than you might think. In the end I just cut a strap off of an old hunting vest.) I burned holes in the strip with a heated screwdriver tip. I ran the strip through the pinch fasteners then riveted it to itself.
I hope any of this makes sense, I'm not the best at explaining things. If you have any questions, just post it or send me a pm. I was a little unsure about how it would turn out, but it really isn't too difficult to do.
