Thanks to Google and the helpful dogs here, I think my first attempt at making a Kydex sheath turned out nicely. I guess dogs are truly man's best friend. <img src="/ubbthreads/images/graemlins/wink.gif" alt="" />
Since my Paratchute Mandu has the most teeth out of the two pant-less blades I have (the other is a Reg), I started with it. Also, I envision the Regulator Bayonet project to be more complex and this gave me a chance to practice.
The knife snaps in gently, yet it is very secure. I held the end of the sheath and shook it hard in a downward motion and the knife didn't show any signs of losing its grip in the sheath. However, I had an extra button strap in my scrap box and wanted to make absolutely sure it wasn't coming out. I pulled as hard as I can with the strap snapped and couldn't get the knife out.
I opted for a horizontal carry arrangement so I can put it on my belt above my pant's fly. This way I can have it concealed under my groin flap on the flak jacket. It is also uncomfortable and awkward to have a knife strapped vertically on a belt when wearing a flak. The handle either get caught under the jacket or is pushed out making the bottom of the sheath press into your leg.
I saw this cord cutter groove online somewhere and thought it would be a good addition. It works as advertised. It is very easy to cut paracord without unsheathing all those teeth.
For clarity, this is actually my second attempt. The first attempt resulted in a bubble or something in the Kydex. The definition of the blade was lost in the plastic. I think my press might have bunched the Kydex up when pressing or I didn't get the press on the material before it cooled too much. Since Kydex is fairly forgiving, I just put the messed up pieces back in the oven and tried again. Second time is a charm.