As promissed I have here the tutorial for my kydexsheaths

This is the way it starts:

http://www.ansoknives.com/k1.jpg<font size=1 color=#eeeeee>. (http://www.knifekits.com/kydex.htm)</font>

The tools, a knife and some Kydex. I use a heatgun to heat my kydex. I have cut the kydex oversize for this project as for all others...never try to save material by cutting the Kydex just big enough....you will mostly have to litle and then use more than you would have if cut oversize.

http://www.ansoknives.com/k2.jpg

I use a piece of plywood with smooth surface as a working plate...in this case it is the lower piece of my kydexpress...the toppiece is same size plywood with 2-3 layers of blue sleepingmat glue on with sprayglue. I use maskingtape on the blade to leave enough room in the sheath to avoid skratches.Using cottongloves I am getting ready to heat the kydex...watch out where you put the knife in this process!

http://www.ansoknives.com/k3.jpg

The handle of the knife is placed outside the working plate close to the edge. The hot kydex is placed on top.


http://www.ansoknives.com/k4.jpg

The "sandwich" is clamped down and left to cool of for 5-10 minuttes

http://www.ansoknives.com/k5.jpg

This shows what will be the top of the sheath. (I ussually make "pancake" sheaths...putting two pieces of kydex together.)

http://www.ansoknives.com/k6.jpg

Now I mark for the eyeletholes. I use a master made from aluminium with holes matching a Tek-Lok...this way I am sure that no matter how I put in the holes they will allways fit a Tek-Lok. I make my own beltclips (more later) but like to be able to use the Tek-Loks. Marking one hole I make sure not to move the master and then mark the next.

http://www.ansoknives.com/k10.jpg

I put 6 eyelets in this kind of sheath....hence 6 markings.

http://www.ansoknives.com/k12.jpg

I put front and back together and hold them with Kant-Twist clamps and go to the drillpress

http://www.ansoknives.com/k13.jpg

Using a wooddrill with the special point I drill the holes. I don´t use regular drillbits as the graps the kydex and ruins the holes if you are not carefull. Besides the tip make it easy to hit the right spot.

http://www.ansoknives.com/k14.jpg

Here are the two parts. Be sure to clean the inside for any dust before putting in the eyelets.

http://www.ansoknives.com/k15.jpg

6 eyelets and the right tools. I use the anvil on a cheap vise for this process.

http://www.ansoknives.com/k16.jpg

Starting on one eyelet....not finishing the peening but enough to keep the two parts together. The I set one in the oposit corner to align all the holes.

http://www.ansoknives.com/k17.jpg

All eyelets set I go to the bandsaw

http://www.ansoknives.com/k19.jpg

and saw roughly to shape...do not go too close!!

http://www.ansoknives.com/k20.jpg

Now I take it to the beltgrinder and carefully grind to shape using my contactwheel and small wheels. The I buff the edges using a hardsewn wheel with very litle polishingcompound. I sue this rough red waterbased type.

http://www.ansoknives.com/k21.jpg

next it is time for the beltloop. I have cut a piece of kydex approx the right size leaving it plenty long.

Using aluminium profiles to press the hot kydex around a steelbar the same size as a regular belt.

http://www.ansoknives.com/k22.jpg

Here it is cooling of while I press it down

http://www.ansoknives.com/k24.jpg

trimmed and buffed I drill holes and champher them so it looks cool.

http://www.ansoknives.com/k25.jpg

I give them my "ANSO" stamp

http://www.ansoknives.com/k26.jpg

Finally I use a rag and some Acetone to clean/buff the edges.

And the final packages...!

http://www.ansoknives.com/k27.jpg

http://www.ansoknives.com/k29.jpg

And as promissed a look on how to attach the Tek-Lok. I use two screws and the fit all the holes on the sheath for multiposition carry.


end of tutorial.

Great job, Jens!

What a great tutorial!

Excellent job ...Your Sheathness!!!! :)

Alex

Where can I buy kydex?

What size eyelets do you use?

I use 8-8 eyelets...I had to find some different setting tools and use the base from one set and the punch from another as we have metric over here.....

I use 1/4" screws and posts

Kydex can be bought at the larger suplly houses.

gonna stick this to the top for a few days........

Sharing is a great way to keep the knifemaking professional on top. Your tutorial took a lot of work and time. We appreciate your efforts! As suppliers we make every effort to keep on top of what we sell and this helps us help others. I will see that every employee sees it! Thank you, Venice

Best tutorial I've read. I just have one question, how hot/soft do you want to make the kydex before you start to mold it?

I make it HOT......not so hot that you ruin the plastic...it will shrink and burn on you if you heat it too much...but it needs to feel like wet leather.....best way to describe it I think.

Thanks, that makes perfect sense. Thanks for the quick response. This is the first time i've worked with kydex and I'm kind of flying blind.

Jens,

Thanks very much for making this tutorial - I have been looking for a clear and descriptive write up like yours.

Question: in your third picture you have the hot kydex being placed on top of the knife - did you heat it first and then place it on top of the knife, or is it okay to heat it with the heat gun while the kydex is sitting on top of the knife?

Do not heat the kydex with the knife near!...it will ruin it...epoxy can´t take the heat...most handlematerials can´t either...

Glad you like it!

Thanks for the tutorial. Gives me lots of starting points for my first try at kydex.
Tom

Jens great tutorial !
Where do you Buy the aluminum friction nuts that you use for your belt loops,I have looked all over for those things and cant find them anywhere.
Thanks a bunch.
Lucas

Luc -

They look a lot like the screws that are supplied as standard with TekLoks. Blade-Tech will sell you them separately ($1.95 a pair, IIRC - if anyone knows a cheaper source...?).

I have another question for Jens - how do you stamp the Kydex? I've been experimenting with warming a small area, then using my stamp, but I haven't been satisfied with the results.

Thanks a bunch!
I thought I'd never get a response on that one.
I Guess I'm going to have to go through blade tech,they are a little pricey, no one else seems to have them.
Lucas

Ps-Bond...I just stamp it...whack it with the hammer but go gentle as it hit to hard it will deform the kydex pretty bad...

If you don't mind Jens,

Where did you get your rivet setting tools? I can't seem to find hand held ones anywhere?

Any help will be appreciated.

I brought a piece of kydex with alot of eyelets with me to a leathershop...they had what I needed but I had to try different punches with different anvils to get the result I wanted...probably due to metric vs inches

Thanks. I'll try that out. Now to find a leather shop.

Originally posted by Ansoknives
Ps-Bond...I just stamp it...whack it with the hammer but go gentle as it hit to hard it will deform the kydex pretty bad...

Cheers, Jens - gave it a go, needed to use a solid tap with a 2lb hammer with the Kydex resting on a small anvil - but it worked well. My stamp has a bit more surface area than yours, I think.

Peter

glad it worked out!!......kydex is FUN

Anso - How big and thick is your piece of aluminium for the belt loop?

Thanks for the tutorial. I've never made a sheath from Kydex but this would certainly help me to get started. I was wondering. Can Kydex be welded? I have a plastic welding rig which blows hot air to weld plastics. Has anyone ever tried heating the ends around the sheath to weld them together? Or will this burn/ruin it?

Roger
part-time maker
My site (http://aliensphere.com/knives)

Thankyou very much Jens, you have inspired me to make kydex sheaths, I can only repay this great thing by letting others in on this, and sharing what you have tought!!

Joe.

:p Excellent tutorial! Thank you.

Do you have to use those big eyelets to hold the peices together? They kind of limit your design options. Would smaller rivets work?

You can weld Kydex. I think the kydex manufacurer has specs on how to do this.

Joe.

fishguy,
I use a diffrent rivet in my sheaths. Rivets and tools availible at www.northcoastknives.com .

Joe.

Hi Guys, I am new to this forum. I want to know what kind of heat gun(how many watts) do you use to heat the kydex? Also would buying a kydex molding press makes the whole process easier? I want to make a kydex sheath for my knife. Thanks