Reddit reviews SIBE-R PLASTIC SUPPLY 5 Kydex Plastic Sheets Black 12" X 12" X 1/16" (0.060")

I think kydex might be a good choice. It is pretty cheap, and also heat moldable. Just make sure to check the thickness of the sheets before you buy. If they are too thick, they won't be very flexible. The .060 inch thickness is pretty stiff, but still bendable by hand. You can pop it in the oven and then lay it on a cylindrical object to achieve the desired curve, and then use a heat gun (or a candle, if you're feeling cheap) if you want a more custom fit.

https://www.amazon.com/Kydex-Plastic-Sheets-Black-0-060/dp/B00HAS1VSK/ref=sr_1_4?s=industrial&ie=UTF8&qid=1495674072&sr=1-4&keywords=kydex

Otherwise, I have also had luck with those flexible plastic cutting boards, like these:

https://www.amazon.com/Flexible-Plastic-Cutting-Colorful-Kitchen/dp/B01HN7ZGUQ/ref=sr_1_2?s=industrial&ie=UTF8&qid=1495674423&sr=1-2&keywords=flexible+cutting+boards

They are pretty good for making crud-catcher type fenders, with liberal use of zip-ties, of course.

Good luck!

Sure!

Basically, you need a few things: kydex sheet, heat gun (or oven, if you wanna do this at home), thermofoam, some wooden planks and G-clamps, hacksaw (Dremel would be better), eyelet (make sure you have the correct length and size) and eyelet setter, and teklok (belt attachment).

First, you wanna cut the kydex into the size that you want to use. I used taco style, so I wanna make sure the sheet can hug my knife.

Then you heat up the kydex sheet with the heat gun (or oven) until it becomes soft. Put the knife between the kydex sheet taco style. Press it hard with the thermofoam. Sandwich the thermofoam with wood planks and secure it with the G-clamps. After a few minutes, the kydex will cool down and you will have a roughly shaped sheath.

Draw outline on the sheath with pencil based on how you want the sheath to look like. Trim the sheath to size using hacksaw (or Dremel). Give about an inch slack from the blade area of the sheath.

Drill some holes on the sheath. I used 1/4" drill bit since I am using 1/4" eyelet. I also made sure that the holes are aligned with teklok holes, so I can attach the teklok using those holes (I messed this part up). Set the eyelet on those holes.

You are basically done here. You could use some sandpaper (or Dremel with sanding attachment) to smooth the edges of your sheath.

Hope this helps. There are many different guides out there, if you find mine confusing.

Cheers.