I decided, with all the knives I'm buying, I need to save some money on sheaths, so I'd better learn how to bend some kydex. Here are my feeble attempts at doing so. I will say, after doing this, I have a lot more appreciation for the level of craftsmanship that goes into the work of a guy like David.

First, I did my Scrapper 5. This one I didn't use a press, just a towel and some body weight:





The I decided, for the bigger sheaths, I was gonna need to make a press. A trip to walmart for a foam camping mat and some spray adhesive allowed me to make a simple press. Some clamps I already owned finished it off.

First victim, the waki:







And then the brand-new desert dogfather:








The hardest part is definitely getting the retention right for the area around the handle. I found the easiest technique was to clamp the knife in the press with only the handle part sticking out, and use a hair dryer to shape it. It wasn't perfect but it got the job done.


Next time, I will wrap the blades in tape or something - not to protect them, but to make the sheath just a bit looser. The waki is a VERY tight fit.

I also didn't have the proper rivet tool, so I flared the rivets with a hammer and a screw head. They don't look awesome, but they do the job.

Well, they look... like I'll keep having a pro make mine. <img src="/ubbthreads/images/graemlins/wink.gif" alt="" />

Actually they don't look half bad, a little smoothing on the edges and you're set.

As long as they get better each time you do it you're good to go.

Beauty job! <img src="/ubbthreads/images/graemlins/thumbup.gif" alt="" />

Those look [censored] good MM!!!

Really nice looking job there for your first sheaths!!!

What did u use to clean the edges up with? A file or bench grinder? Did you need to buy any special tools to make them?

I used a belt sander to smooth the edges. I wasn't terribly concerned about making them super nice, just wanted to take off any sharp bits.

The only things I bought were the supplies to make them, and the foam mat I used to build the press, using some scrap plywood I had laying around. The only other tools used were a cordless drill, belt sander, a couple of quick-adjust clamps, a hammer, the oven, and my fiance's hair dryer. And I used my table saw to cut the kydex, but mostly because it was already set up from when I was building the press.

Good job <img src="/ubbthreads/images/graemlins/shocked.gif" alt="" />!! Soon you will be taking orders <img src="/ubbthreads/images/graemlins/thumbup.gif" alt="" />

I'll leave the order-taking to the pros... a lot of work goes into those little folded bits of plastic, and I did mine with a lot of lazy corner-cutting. I wouldn't want to put in the work it takes to make a nicely finished product.

Those look pretty darn good, MM. Is that 0.090" thk kydex?

I ordered the 0.08", but I haven't actually measured it. I'm thinking about trying the 0.06" next time I order some, to see if it shows the outline of the blade shape better.

Very nice. You've been busy.

very cool man ... ill probably be joining you into this hobby next month. im still going to buy some pants from people but i might start bending my own till those orders show up... that and other options would be fun.

I think the thinner 0.060" kydex (I've tried 0.090") will give an easier release. That's my next kydex. I was initially worried about durability, but after heating and forming the thick stuff, I don't think that durability will be an issue with the thinner kydex.

Good job MM! <img src="/ubbthreads/images/graemlins/thumbup.gif" alt="" />