Hope you guys find this useful. This stems from my desire to be named "Cheapskate of the Year." Hope this helps some of you out there.
This is my moulding press for making Kydex sheaths.
The blue foam is the type used in thin sleeping rolls for camping - easily avaialble in 6 foot lengths. I use a heat gun on a high setting to heat the kydex, holding it with a pair of pliers. Then mould it to the shape I want. I insert the hot kydex into the fold in the foam and press down hard with the plate of Micarta - kinda like doing CPR, using your whole mody weight through straight arms onto the plate. You can modify the angle of the pressure, the tapers of the sheath and the tightness of the moulding quite easily with some practice. Holding down the mould for up to a minute makes for a very tight, clean fit. I adjust the fit and retention with a cigarette lighter or a small tea-light candle.
Cheers. Jason.