Knife Sheaths Using KYDEX® Thermoplastic Sheet TB 144

ADVANTAGES OF KYDEX® SHEET SHEATHS & HOLSTERS

There are a number of different ways to construct a knife sheath or gun holster. Within this technical brief are some of the more common ideas in the construction of knife sheaths and gun holsters when using KYDEX® sheet. It is generally used because the sheet is easily formed under the heat from a heat gun and it is also resistant to normal wear and tear from the knife blade. The most common thicknesses range from 1.52mm (0.060”) to about 3.18mm (0.125”).

• Highly durable for continuous use
• Great color selection including custom color matching
• Easily molds to contours of the knife or gun
• Water, chemical, and stain resistant
• Can be re-molded
• Easily cleaned off with household cleaners
• Can be used as a liner for leather sheaths and holsters

POSSIBLE TOOLS FOR SHEATH CONSTRUCTION

• Hair dryer or heat gun for heating KYDEX® sheet
• Foam, neoprene, small towel, etc. to wrap around knife or gun before pressing sheet around knife or gun
• Masking tape to tape off towel, neoprene, etc.
• Sheath Press to form KYDEX® sheet to the shape of the knife or gun
• Adhesive compatible with PVC (solvent cement, adhesive, hot gas weld)
• Rivet Press and rivets for seams of holster
• Drill and drill bits to pre-drill rivet holes
• Belt loop pre-molded or fabricated
• Screws to attach pre-molded belt loop to sheath or holster
• A type of saw to cut out the molded piece of KYDEX® sheet
• Sandpaper or scotch brite pad to finish the sheath once constructed

TIPS FOR SHEATH OR HOLSTER CONSTRUCTION

Safety

• Cotton or heat-resistant gloves are recommended during the heating and forming.
• Never use an open flame to heat KYDEX® sheet because it will burn.

Cutting and Trimming:

• The sheet or final part may be cut with a circular saw or band saw
• A 0.30m x 0.30m (1’ x 1’) sheet is a recommended size for making a sheath or holster

Heating:

• It is important to keep the KYDEX® sheet to about 166-193°C (330-380°F) while forming. The sheet will burn at a temperature greater than 204°C (400°F).

TIPS FOR SHEATH OR HOLSTER CONSTRUCTION

Forming:

• Sheath press is recommended when forming the KYDEX® sheet to the knife/gun.
• Sheath presses may be constructed out of wood & neoprene foam or may be purchased at www.knifekits.com.
• A towel or neoprene can be wrapped around the blade to create space during molding so the knife/gun can be released from the sheath/holster and keep the blade from being scratched.
• KYDEX® sheet can be wrapped around the knife/gun like a common leather sheath/holster or be made into two pieces.
• An area that is stress whitened may be reheated to bring the color back into the sheath being formed.

Assemble and Finishing:

• Be careful to leave enough material to connect the edges of the sheath/holster for a strong bond by rivets and/or adhesive.
• Rivets are a good way to connect the edges of the knife sheath/gun holster.
• A high strength adhesive is also recommended when using a bonding agent to connect seams of the sheath in conjunction with rivets. (see our Technical Briefs on our website for )
• Leaving a small slot or hole at the bottom of the sheath/holster will allow for better drying when cleaning.
• Belt loops may be constructed with the extra material not used in the forming operation.
• Finishing of rough edges after sheath construction may be done with sandpaper, etc.

For supplies or more information, contact or visit the following websites: