Materials to make this:
1 x CKK Rivet/Eyelet Flaring Dies – Journeyman Series – #8 – (1/4) $24.95
1 x KYDEX™ Sheet – (.08 Black) $5.70
1 x Eyelets – #8-8 (1/4) – Black Finish – (for .080 KYDEX™/HOLSTEX™) – 100 Pack $12.95
1 x Belt Loops – Tek-Lok – (Large) $10.75
1 x Sheath Making Foam – (12×11.5×1) – (KYDEX™/Concealex) $10.95
1 x Chicago Screws – Black Coated – #8 – (.1875 x .250) – 10 Pack $3.60
There is a mini tek-lok version which would be lighter but I decided on the Tek-Lok large because of the built-in fail-safe as oppose to the mini where its a separate piece that you might lose. The fail-safe prevents you from accidentally unclipping your sheath.
I made my own kydex press instead of spending $85 for one. I purchase the sheath making foam since it rated to take high temperatures. I cut the foam in half to make my press. 6×11.5 is good enough for the sheath sizes that I will be making.
For the press I used two 12x12x3/4 wood board, two 12x1x3/4 and a old hinge that I found.
Prepare your blade with 2 layer or masking tape on both sides. This will provide a nice little gap to prevent debris from scratching your blade.
Pre-measure the kydex to wrap around your knife. Cut it in 1 sheet so that you would fold to cover the knife. Score the kydex with a blade or hobby knife. You don’t need to cut all the way through since you can snap it easily. I cut mine to 4×12.
To heat the kydex I used a $7 heat gun from Harbor Freight. You can also use a toaster oven, just keep close watch. Wear gloves, it gets hot. Its ready when you can flap the kydex around like a piece of paper, fold it around your knife.
Put the entire setting to the press and you can stand on top of it or clamp it down for 5 – 10 mins. I found that clamping it and then screw tight the clamp yield best results.
Draw a pencil out line from the shape of the blade on your kydex sheath. This outline should give you an idea of the final shape of the sheath.
Pre-mark the holes with a pencil with the tek-lok mounting holes as a template.
Use a 3/16 drill bit to drill the holes.
Make sure you clear any debris that might be sandwiched in your sheath before you tap tight the rivets.
More pics to come when I get the chance.
I forgot to mention I purchase all my stuff from knifekits.com