My ghetto way to make sheaths...

wolffbite

wolffbite

Joined
May 7, 2010
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Maybe this isn't meant for shoptalk but I've had some interest in pms and comments how my sheaths turn out so "nicely" (I still think there is plenty of room for improvement but those are your compliments and not mine! lol). I also figure this could be of help to other newer knife makers who want to get into making kydex sheaths but think it may be too costly.

Here is my "press". It is basically a couple of 5"x12" pieces of scrap ply, held together with some old door hinges... the 1x4's are for some extra support and the long piece of ply is so I can get some leverage on it to squeeze the crap out of it. I bought an 11.5x12 piece of kydex foam from knifekits and sliced it in half to fit my narrow press. I then bolt this to an old work table... and carry it into the kitchen...

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Notice my awesome "shop". It is a good thing mom isn't around when I make sheaths... and it is also a very good thing that I haven't yet stunk up her kitchen by melting kydex in the oven!

I think the reason I get such good results is because of the amount of pressure. I'm pretty sure that 50% of the time a sheath fails to be formed properly is because the kydex isn't hot enough to mold, and the other 50% is not using enough pressure to mold it. If you think you have enough pressure.... press it harder.... press it until you think your press might fling apart.

I have a pan with parchment paper and a small rock on the sheet in a 375F oven. I put the piece of kydex on top of the rock... wait until it starts to droop over the rock... reach in there and pick it up... and if it folds over easily like a noodle it is good to go!

It was far too annoying to press down with my body weight for 5 minutes every time I wanted to make a sheath or belt loop... so I rigged up a very sophisticated tension device.... a piece of paracord with 2 carabiners...

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Yep that is how I make kydex sheath's on the cheap.

Here is the knife I just sold to my buddy and the loop he requested. All done with the above tools...

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Anyways... that's just my way of doing it. There are better ways, and the kydex pros will probably get a good laugh out of this :D. But hey, all this "press" cost me was the price of the foam!

Thanks for reading ;)
 
Good tutorial Wolffbite. I was going to do something similar but I found a used molding press for cheap on craigslist (same large model sold by knifekits).
I am curious on how long this molding foam lasts, 10 sheaths,50,100?

Can you use the outer edges of the foam to mold when the center gets worn, or should you replace the foam when the center is worn and not use the outer edges surrounding the center?
 
Neat press.

I wouldn't use my kitchen oven; the fumes produced from heating kydex are not good for you.
 
Blandies -
Ive had my kydex press(knife kits) for about 3 years now, made probably 30+ sheaths and still have not had to replace the foam.
 
Interesting. From what I've read the temp where kydex will start to bubble and literally "melt" is 425F. Most recommended working temps I have found are 350-375F.

Perhaps I'll knock it down to 325-350F, i only chose the higher end to get it up to heat faster so I wasn't taking up the kitchen for too long :p

@blandies I've made ~10 sheaths now with this foam... so I can't comment on how long it should last. But I think if you have to get into finding unscathed areas on the foam you should probably just replace it to save any headache. Knifekits sells bundles of foam cutoff's for cheap that would be the perfect size for this size of press
 
Cool stuff!

Try 275-295F it will still work great and produce less toxic fumes. I feel that I only notice the fumes if the oven is too hot... I wear a respirator when making them I know that.

I use that blue foam (for camping - under sleeping bags) and it will do maybe 50 sheaths before you really need to change it in my opinion. I dont even have a press, I just spray glued some foam to some plywood and clamp it. Super cheap and effective!

That sheath is looking great, nice job!
 
A rock?! That's a great idea. I'll have to try that when I make another Kydex sheath. The foam I used has made well over 10 sheaths. I sometimes wipe the foam with a rag that has a little WD40 on it so the Kydex doesn't stick as much.

I use a toaster oven between 300-350°F. I've heard of some knife makers that have gotten in trouble with the Mrs. when they tempered some knives that had a little bit of residual quench oil on them during tempering. Dinner must have had a hint of quechant that evening.....:barf:

Ric
 
I have my kydex oven set at 275F, which my little oven thermometer confirms. My thermocouple rig says this is actually about 295F. I have encountered problems with the Kydex shrinking if it gets much above 350F. How long you leave it in the oven makes a difference also, leave it in at 375 for very long and I expect you will get some shrinkage and the seams may try to weld together in the press.
 
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