I'm lacking in any sort of power tools (well, I have a drill and access to a belt sander), and can't afford to go get a dedicated Band saw for cutting finished sheaths to shape. What do you guys use that is relatively low cost and non-powered if possible? I need an easier way, 'cause the scissors just ain't cutting it! (pun fully intended)

Light saber? <img src="/ubbthreads/images/graemlins/grin.gif" alt="" />

Jigsaw may cut it, not sure. Never tried to cut Kydex.

I would say utility blade with a metal ruler to give you straight edges. may take a few runs depending on the kydex and cuts. for detail work I would thing a coping saw or jigsaw might work. sand paper and hot air gun for even more detail. a dremel is really cool to have around as well..

I did a search on kydex tutorials a while back and found quite a few dyi guides and threads. it's something I want to get into but just haven't made the time.

Can you score it with a razor knife and then break it? That would get you close anyway.

razor knife is the non power way to go

To cut the rough size out, a straight edge and utility knife works well. Score it deep and then bend it back a time or two till it snaps.

After molding I sometimes cut it close to final size with offset tin snips. I just do one thickness at a time with the snips not through both sides at once. This helps to reduce sanding.

For final finishing I use a belt sander, and or dremel with the little sanding drums.

I am far from a pro at this and still learning myself.

rough shape is done with utility blade like others (bending and such). further shaping is done with a scroll saw (should be <$100 at harbor freight or even less on craig's list/ yard sale). finish with sand paper on the mouse pad. YMMV

I used a coping saw before i got my jig saw. It was $5 at harbor fright. I found this to be the best option without a jig saw because it allows you to cut curves and you end up with less finish work. Search for coping saw on HF website. Have fun with the kydex man. <img src="/ubbthreads/images/graemlins/thumbup.gif" alt="" />

This is an example of the contours and curves I am talking about.

What methods are you using for "shaping" the kydex to fit your blade? I've read about people dunking the sheet in boiling water, using a heat gun, and I've even used a blow-dryer to final shape one that I bought (which didn't fit quite right).

I wrote up a tutorial here a while back for Kydex, but I cant find it. I use a toaster oven at 300 degrees for several minutes to heat it up for the initial bend and then use a heat gun to finish fit the handle. The finish fit is the tougher part. A heat gun does not work as well because you cant get uniform heat. I have done it, but the result is not nearly as clean. Once its nice and plyable I wrap the blade and part of the handle and put it in a press for about 30-60 mins.

I need to find that darn tutorial since a picture is worth.......

I'd love to see the tutorial, because I've spent about $450 on kydex sheaths during the past 2 years <img src="/ubbthreads/images/graemlins/barf.gif" alt="" />

Yeah thats what put me over the edge. First came Kydex, then and now, I am hooked on leatherwork. I will dig it up.