Kydex sheaths and holsters

[hollywood]

Hey gang,
So I have recently expanded my skillset to making knife sheaths and holsters from Kydex. There may already be a thread on this topic, but I have not come across it. I was looking at the Landfall ODST reference pics, and I love the way that shoulder mounted blade looks, so I'm going to try and replicate it if possible for my kit.

Once I finish gathering the necessary tools, (need a rivet press), I will post a tutorial for the process. With the exception of the rivet press, most of us already have the necessary tools in our armor building equipment. I figured this might come in handy for some of the folks doing blades for their spartan 3 builds.

 

[Rosh]

Definitely looking forward to this. I'm just now making knives for my current project, and made 1 sheath already from styrene, can't wait to see how this is done.

 

[Toacrabman]

I know they make that knife because its some kind of survival knife that already exists, so you can buy it.
I remember somebody posted a link to it on the WETA style ODST thread. So whatever you do dont sell them or they could take some form of agressive legal action.

 

[hollywood]

Yeah, it was the Kershaw Responder Model.
http://www.knifeworks.com/kershawresponderblackhandlecomboedgekydexsheath.aspx
Im wanting to replicate one with a non-steel blade for the kit. I own plenty of live blades, but I dont want to be carrying one around at a Con or anything. Never had any intention of selling, just making a one time copy for myself. Wanted to post the walkthrough for those that might be looking for an easier way to make sheaths than pep.

1. Source for Kydex sheeting: http://www.knifekits.com/vcom/index.php?cPath=41_54

2. You can purchase a "sheath making Kit" which comes with several additional parts but these are the basic items you will need. All of these and most of the Kydex specific tools can be found at www.knifekits.com under the sheath making section.
-Kydex roll rivets: either #6 or #8 depending on the thickness of Kydex used
-Chicao Screws
-Mounting device: this can either be a belt loop made of kydex, nylon, or metal, or a Tek Lok mount (my favorite)

3. Tools you will need:
-Heat Gun/Toaster oven
-Kydex Press (I will tutorial how to make a simple one on the cheap)
-Power Drill
-Kydex drill Bits are nice, but not totally necessary.
-Rivet flaring dies (you can also buy the $70 rivet die press......I didnt)
-A bench vice if you want to forgo the die press
-Hammer
-Razor Blade
-Grinding wheel/Belt sander/Dremel or some grinding tool
-200-600 grit sandpaper
-Rivet polish (totally optional)



More to come with Pics

 

[hollywood]

So, before you do anything else, I would recommend building your Kydex press. It can be as complex and fancy as you want, but I tend to go for spartan and cheap, as long as it gets the job done right. I took a 1X 12 and cut it into 15 inch sections, created a section from a piece of 2X4, and added some hinges. Add a few layers of EVA foam or Neoprene, (EVA is MUCH cheaper per bulk, and has worked just fine for me. If you're going to make hundreds of sheaths, splurge for the neoprene.)

 

[Toacrabman]

I find it to be quite a failure that all of the WETA ODST's are using "combat knives" with BLUNT TIPS, for safety reasons. XD

 

[Sidewalker4961]

Thanks for the tips. I found a nice knife. This will help me make a sheath for it.

 

[hollywood]

Sorry for the lack of progress guys. I'm still waiting on the old man to send me his blade so I can do the demo sheath for it. If its not here in a few days I'll just pick up a cheap Mora for the sake of the tutorial. Wanted to do one on his Ontario RD-7 since the contours are roughly similar (at least in size) to the reach blade.

 

[TheSauce05]

I've lurked on the forums for a little bit now and this is my first post, so forgive me if it sounds silly, but why not buy the Kershaw, then vacuum form the knife, replicating the handle, and use the Kydex sheath that came with the knife along with your vacuum formed knife when you don't want to be carrying a real one? Since you're not actually going to be using the knife it should just stay sheathed anyway, right? You can pick those knives up for around $20 with the sheath.

 

[IronicTrout]

Good tutorial start. I can't wait to see the end result!

 

[hollywood]

I've lurked on the forums for a little bit now and this is my first post, so forgive me if it sounds silly, but why not buy the Kershaw, then vacuum form the knife, replicating the handle, and use the Kydex sheath that came with the knife along with your vacuum formed knife when you don't want to be carrying a real one? Since you're not actually going to be using the knife it should just stay sheathed anyway, right? You can pick those knives up for around $20 with the sheath.

That is certainly a viable option. And for those that would prefer to do it that way, more power to you. I actually picked up a resin cast of the Kershaw from Thorsolli, which is a perfect reproduction and is going to work wonderfully for my kit. I just figured I'd throw up this tutorial for anyone interested in making kydex sheaths.

I appologize for the lack of progress. I still have not recieved the ontario from my dad. He is lazy but i loves him anyways. I will finish the tutorial on a blade I have on hand. Just didnt want to waste the materials on a knife that did not need a new sheath anyway.