Do you have a knife or a tool that you want to carry with you on your outdoor adventures? A kydex sheath is a great way to safely and securely transport your blade without worrying about accidental cuts or damage. In this article, we’ll show you step by step how to make a kydex sheath using simple tools and materials that you might have lying around your home.

Kydex is a type of thermoplastic that’s used in the production of many everyday objects, including gun holsters and knife sheaths. It’s a lightweight, durable and heat-resistant material that can be molded and shaped to fit any object. Making a kydex sheath is a relatively simple process that requires only a few supplies and little experience. With a little bit of patience and effort, you can create a custom-made kydex sheath for your knife or tool that will last for years to come. So, let’s get started!

Choosing Your Materials

When making a Kydex sheath, choosing the right materials is crucial. Here are some materials you will need:

Kydex Sheets: These are thermoplastic materials that are used for moulding and shaping the sheath. They come in various colors, textures and thicknesses. The thickness you choose will depend on the size of your blade.
Knife: For obvious reasons, you will need a knife to make a Kydex sheath. The blade size of your knife will help you determine the Kydex sheet thickness you need.
Eyelets: Eyelets are used for riveting the sheath and attaching it to your belt or backpack. Choose eyelets that are compatible with your Kydex sheet thickness.
Rivets: Rivets are used to hold the eyelets in place. Choose rivets that are sturdy and rust-resistant.
Tape: Painter’s tape or masking tape will be used to hold the Kydex sheets together when heating and forming them. Avoid using duct tape or any other tape that may melt or leave residue on your sheath.
Belt Clips: Belt clips are used for attaching your Kydex sheath to your belt. They come in different sizes, and you should choose one that will fit your belt and sheath comfortably.
Tools: Depending on the method you choose to make your Kydex sheath, you will need some tools like a heat gun, drill, rivet setter, etc.

Preparing Your Workspace

Once you’ve gathered all your materials, you need to prepare your workspace. Here are some steps to follow:

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Cleanliness: Ensure that your workspace is clean and free from debris. You don’t want any dirt or dust particles to get in between your Kydex sheets when heat is applied.
Ambient Temperature: Kydex sheets require a specific temperature to mold correctly. Ensure that the ambient temperature is warm enough to make the Kydex pliable. A warm room or a heat source will be sufficient.
Clamp: Fix your Kydex sheets to a clamp or any other holding device to keep them in place while heating and forming.
Heat Source: You will need a heat source like a heat gun or oven. Ensure that the heat source is a safe distance from your workspace to avoid any accidents.

Forming Your Sheath

Now, let’s dive into how to form your Kydex sheath. Here are the steps you need to follow:

Trace Your Knife: Place your knife on the Kydex sheet and trace its outline. You will need two identical pieces of Kydex for the front and back of your sheath.
Cut Out The Pieces: Using a utility knife or scissors, cut out the traced Kydex pieces. The edges of the cut pieces should be as smooth as possible for better attachment through riveting.
Tape The Pieces: Tape the two Kydex pieces together using painter’s tape or masking tape to form the sheath. Ensure that you tape the pieces tightly to avoid the sheets slipping when heating.
Heat The Kydex: Use a heat gun or oven to heat the Kydex. The Kydex will become pliable once it’s heated to the right temperature. Spread the heat evenly across the Kydex sheet to ensure that it softens evenly.
Mold The Kydex: This is the part where you shape the Kydex around your knife. Once the Kydex is heated, take it off the heat source and place it over your knife. Press the Kydex down onto the knife and mold it to the shape of your knife. Use your fingers to work the Kydex into the contours of your knife handle.
Remove The Knife: Allow the Kydex to cool and harden before removing the knife. Be careful not to break the Kydex while taking out the knife.
Set The Eyelets And Rivets: Drill the holes for the eyelets and rivets using a drill. Insert the eyelets and rivets and secure them in place using a rivet setter. By now, you have both parts of your sheath ready for attachment.
Attach The Belt Clip: Attach the belt clip to the Kydex sheath using the screws provided. Make sure the screws are tight enough to keep the clip firmly in place.
Trim The Edges: Trim the edges of the Kydex sheath using a utility knife. Ensure that the edges are smooth and free from rough spots that may cause injuries.
Clean The Sheath: Once you’re done trimming, clean your sheath using a damp cloth. This will ensure that your sheath looks polished and professional.

Conclusion

There you have it – your very own Kydex sheath. With a little bit of patience, anyone can make a Kydex sheath for their knife. Remember to take your time, follow these steps carefully, and ensure that you use the right materials. As always, enjoy the process and have fun with it!

10 Steps For Making Your Own Kydex Sheath

If you’re looking for a protective and functional sheath for your knife or other sharp tools, making a kydex sheath is the ideal solution. Here are ten steps to guide you through the process.

Step 1: Gather Your Supplies

Before you begin, gather all the essential tools and materials for the job. This includes kydex sheets, a heat gun, a belt sander, a pair of scissors, a marker, gloves, a drill, drill bits, a ruler, and a rubber mallet. You can purchase a kydex material kit, which comes with almost all the materials you’ll need.

Step 2: Measure Your Knife

To get started, measure your knife correctly. Use a ruler to measure the length and width of the blade, and mark the size of your blade on the kydex sheet.

Step 3: Cut the Kydex Material

Once you get the measurement, cut the kydex material by using a pair of scissors accordingly.

Step 4: Heat the Kydex Material

Use a heat gun to heat the kydex material until it becomes pliable. It’s essential to ensure that it heats evenly and doesn’t get burnt.

Step 5: Mold the Kydex Material

After heating the kydex material, mold it around the knife blade, and form a sheath by applying even pressure.

Step 6: Drill Holes

Once you have a sheath, use a drill to make two holes, the position depends on where you want to attach the sheath, then use a rubber mallet to press the two halves together.

Step 7: Sand the Edges

Use a belt sander to sand the edges of the sheath. Be careful not to overheat and melt the kydex material.

Step 8: Smooth Edges

After sanding, use a heat gun to heat and smooth the edges of the sheath, which gives it a polished look.

Step 9: Attach the Belt Clip

Now, attach the belt clip to the sheath’s back, and you’re almost done!

Step 10: Final Touch

The final step is to polish the sheath with sandpaper to remove any scratches, making the sheath look attractive and free from blemishes.

After following these ten simple steps, you’ll have an outstanding and functional kydex sheath that you’ll be proud to carry with you everywhere you go. Remember, practice makes perfect. If you don’t get it right the first time, try again until you get the perfect sheath for your blade.

Materials needed for making a kydex sheath

When making a kydex sheath, it is essential to have all the necessary materials ready beforehand. Here we will outline the key items required for the job.

Kydex Sheet

The cornerstone of the kydex sheath is, of course, the kydex itself. When purchasing the sheet, it is crucial to ensure that the size is suitable for the blade you are making the sheath for. Also, be sure to select the appropriate thickness of kydex depending on what you need to use it for. For instance, a thicker kydex would be preferred for a sheath that will be used for a sharp blade to guarantee safety.

Knife Blade and Scabbard

Before starting this procedure, you need a knife blade that has been designed correctly and is suitable for encasing. Choosing the right blade will ensure the right measurements and the final outcome of your kydex sheath. But you must also have the scabbard; you might want to keep different types of blades in the same scabbard, and you also need to have more than one scabbard to rotate different blades without pulling the kydex apart.

Clamps or Vise

Clamps are used to hold the kydex sheets together while heating them with a heat gun. The clamps help to ensure that the sheets are under even pressure in the heat gun, resulting in an even molding process. An alternate option to clamps is a vise; a vise can also hold similar pressure when pressing the kydex sheets down.

Heat Gun and Gloves

At high temperatures, kydex sheets soften, making molding possible. You need to have a heat gun to do this process and mold the sheet to fit the blade correctly. Remember to use heat-resistant gloves while handling the heated kydex since it can be dangerously hot and can cause burns.

Eyelets and Rivets

The eyelets and rivets in our kydex sheath tie everything together and hold the product intact. These tools are used to drill holes around the edges of the kydex to attach the necessary straps, belt loops, and other fasteners. It is advisable to acquire rivets that correspond with your eyelets so that all the materials used in the design remain uniform.

In conclusion, it is crucial to acquire all the necessary materials to make a quality kydex sheath. It may cost a little more for some of the materials, but the finished product’s quality will be well worth it.

Happy Sheathing!

And there you have it! Making a Kydex sheath may seem like a daunting task at first, but with a bit of patience and practice, you’ll have a custom sheath in no time. We hope this guide has been helpful and informative for you. Thank you for spending your time with us, and we hope to see you again soon with more exciting projects. Until then, happy sheathing!

DIY Guide: Making a Kydex Sheath for Your Knife