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How to Form a Kydex Sheath

Kydex is a strong thermal plastic that is used for durable sheaths, gun holsters and light holders. This material is molded with the use of heat and a press. When a heat-resistant object is pressed between two pieces or a folded piece, its shape will be captured. This allows sheaths for just about any knife to be created quickly and in large numbers in a workshop. Make a simple press using pads, wood for the casing and clamps.

Things You'll Need

Leather gloves
Tape measure
Straight edge
Chalk, white
Kydex, 1/16-by-12-by-12 inches
Heat gun
2 high-density foam pads, 1-by-6-by-12 inches
2 plywood sheets, 1/2-by-6-by-12 inches
2 C-clamps, 6-inch
Ban saw
Drill
Drill bit, 1/8-inch
12 Chicago screws, 1/8-inch

Instructions

- 1
  Measure 6 inches away from a pair of edges and draw a line across the center of your Kydex. Heat the Kydex gradually using your heat gun. Fold the Kydex in half on the line. The back edge of your knife will be against the inside of the fold.
- 2
  Heat your Kydex again so it is malleable. Fit your knife inside the Kydex so 1/2 inch of the top of the handle is covered on each side.
- 3
  Place the Kydex with the knife inside of it between the center of two pieces of foam, and between two pieces of plywood.
- 4
  Tighten the clamps directly over the cooling sheath so they're spaced 4 inches apart. Let the Kydex cool for 30 minutes.
- 5
  Remove your knife from the sheath and draw a dot every 1 inch that is 1/4 inch away from the outline of the blade edge. Drill a 1/8-inch hole through each of the dots and screw a Chicago screw into each hole.
- 6
  Draw a line that is 1/8-inch away from the screws on the opposite side of knife slot and cut along the line using your ban saw.

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