I recently started looking into making kydex holsters. I did alot of research, and it actually seemed pretty easy from everything I saw. Basically, you heat the kydex, then put it in a foam press with what ever youre making a holster or sheath for, then take it out, trime, put in the eylets, and finish the edge.

I got all my stuff today, and I decided to start off with something quick and easy since I have to be at work later today. Since I use a bar blade for work, I decided to make a sheath for it.

First I started by shaping a piece of wood so that it would leave a larger opening so that inserting the blade would be easier, I then taped it in place.




Then I went ahead and cut out two pieces of kydex, and went ahead and put them in my toaster oven. I start out at 150*, then after a few minutes, bump it up to 200*, then after a few more, bump it up to 250*. Im still getting used to working with the kydex, so I still need to fine tune my heating process.

After it has been in the oven long enough, it will be pretty flimsy. Almost like a sheet of putty. I used some mechanic gloves, and pulled it out, put the bottom piece in the press, then put bar blade, and then the top sheet and closed and clamped the press.

After about 10-15 minutes to cool, I was left with this.




I had to pry the two sheets apart. They were stuck pretty good. But I got them apart, drilled the holes, put the eylets in, and proceeded to cut, sand, and shape it.

I started with this:


And I finished with this:


Heres a picture of the back. I put the belt loop like that so I can have it at a good angle for when I need to pull it out or sheath it.
I need to get an arbor press for the eylets though. The hammer method Im using isnt fully pressing the eylets. They are snug, but look like crap.



This took me about 2.5 hours to do from start to finish. Once I get the hang of it, I should be able to crank out holsters. Im going to go get an arbor press from Harbor Freight tomorrow, and then Ill start making holsters. Probably start with my Sig P228.