This Project was inspired by reading about the law of one state that makes it illegal to carry a fixed blade knife concealed on your person, regardless of size. The solution in that people came up with was to carry a folder, open in a KYDEX® sheet sheath.

This is essentially the same as forming KYDEX® sheet around any fixed blade knife, and I wanted something that could be hung around the neck, or strapped onto a backpack strap. Because of this, thin was important. I used .060 KYDEX® sheet, and cut it to the size you see to the right (under the knife) with the bandsaw.

Next I taped up the knfe to provide a little space when the KYDEX® sheet is formed to it, and to cover the screws on the belt clip so that the KYDEX® sheet didn't get formed right around them.

Then the KYDEX® sheet went into the preheated toaster set at 345 degrees. After about 2 minutes, it was curling up on the sides, so I removed it, folded it like a taco around the knife, and put it into the press, and clamped it all together tightly.

I then let it cool for about 10 minutes. My workshop is roughly 40 degrees this time of year, and so things cool quickly. The more patience you have waiting for it to cool, the better the chances of it being completely cool when you pull it out.

To your left the sheath is being clamped together, while I drill holes for the eyelets and test the hold point.

It is very important to clamp the sheath together where you are planning on putting eyelets, to see if you can still remove and insert the knife. You don't want to get through the process and find out that the knife is either stuck in there, or won't go in. While doing this be very careful of the knife blade it can come sliding out one of the open sides and bite you.

Finishing up:
Next I installed the eylets, using the process documented here. After that I took the sheath over to the bandsaw and started to shape it into the final shape. Next was sanding at the sanding center with 120 grit to smooth out the edges, and smooth the curves together. The next step is on to final sanding.

Finished Product: