I think you can get kydex kits, I'll maybe try one sometime soon. It's not like I'm gonna be doing much fishing for the next couple months!

This will take most of the guess work out if you ever try it. It is a sheath making guide of sorts directly from Kydex.

http://www.kydex.com/briefs/144.pdf

There is deer season, but I'll only hunt about the first week or so of it.

JJ didn't that PDF article you referenced say it started to melt at about 400?

I dipped the opening in boiling water for about 30 seconds to soften it so I could flare the opening after molding it to the knife. That is the only thing that wasn't in the guide.

Not melt.....but BURN!

"It is important to keep the KYDEX sheet to about 166-193°C (330-380°F) while forming. The sheet will burn at a temperature greater than 204°C (400°F)."

I think they meant heat instead of keep.

I can't imagine that turning out well at all!

Don't want my Kydex to be flaming when I'm molding. (Maybe that's where David Brown got his flaming sheath idea)

I heated mine to 190 C. I wanted to give myself the longest amount of working time without risking ruining the materiel.

Unless it's a lot easier than it sounds, I think it would be better to just buy the sheaths already made. But then again, I'm lazy that way LOL

I mean, I wouldn't mind trying it once just for the experience, but seems like a lot of materials needed to do it.