"Kydex" Sheaths - Super Cheap, Home Made Style

[jekostas]

This could probably go under sheaths and carry methods as well, but it seems at home here.

Anyways, I couldn't sleep at about 2AM this morning (thank you medication regimen) and I got to thinking "What waste thermoplastics would people have sitting around at home?"

The answer came to me - used plastic gift cards!  You know those reloadable plastic gift cards you get at Starbucks/Best Buy/iTunes stores?  Yeah - they're generally lightly coated thermoplastic, with a similar thickness to .090 gauge kydex.  I had a bunch of these things laying around since I do restaurant mystery shopping on a regular basis and I've never really liked the sheath that came with my Buck Hartsook, so off to the toaster oven I went.

And this is the result:



I probably should've taken a picture before I painted it, but again this was 2AM in the morning.  Logical thinking skills not at their best.

Anyways, after heating it up in the toaster oven, I wrapped it around the knife, straightened the edges and placed the whole thing between 6 layers of EVA foam between two large hard-bound books.  I then stood on the top book for two minutes to set the kydex.  Took it out, drilled a whole using a Dremel tool, spraypainted it in two layers of Krylon Camo Fusion paint, popped in an eyelet and there we go.  Nice thing about using gift cards is that the edges and corners are already quite nicely finished.

It works really, really well.  The plastic molded to the knife without causing any damage, and didn't shrink or warp in the oven.  The knife also holds quite well with zero danger of coming out.  I'll try this again with my custom Hartsook Talon Lite in a few days.

[Sazabi]

That looks great, Jekostas, do you work on requests?

[jekostas]

That looks great, Jekostas, do you work on requests?

You'll have to send me the knife.

Also, 8 year turnaround.

[Metropolicity]

Fantastic, I wonder if my fiance will be mad if i use the toaster oven...

What temp and for how long did you shove it in there for?

*thinks about micra and PS4 Sheaths.....*

[jekostas]

Temperature?  Time?  I just shoved it on "toast" until it looked soft enough mold.  I also just used the toaster oven on my counter.  No fumes or funny smells so far but YMMV.

[Metropolicity]

I'll have to wait till late and give it a go, I have a TON of those cards lying around.

[tattoosteve99]

About 200f for about 30 seconds for kydex  That's what I use. Not trying to steal your thread

[jekostas]

About 200f for about 30 seconds for kydex  That's what I use. Not trying to steal your thread

No worries.  Anyways, had a little time while I was preparing dinner, so here's a quick visual tour.

1.  The "donor" - a points/rewards card for a crappy discount store.



2.  The card formed around the knife.  I just heated it on toast until the edges curled up.



3.  As you can see it actually forms quite nicely



4.  Drilled some holes with a dremel and a small bit attachment.  I'll clean them up with the awl and serrated blade on my Kf4



5.  Attached a couple of eyelets for retention.  This is pretty well done now, it could be used but I'm going to spray paint it using some Krylon Fusion Camo paint in OD green.  Too late in the day to do it now, though.



Really about it.  Very easy.

[tattoosteve99]

That's a really great alternative to kydex. That would be perfect for the at home DIYer.

[Gareth]

Very cool idea mate.

[Sparky415]

That's a great idea! wheres my old gift cards? 
A hot air gun or a hair dryer might work if you don't have a toaster (works on PVC pipe) 

[enki_ck]

...

*thinks about micra and PS4 Sheaths.....*

My first thoughts too.

Great idea Jekostas

[jekostas]

The really nice thing?  This stuff is proper thermoplastic as well - if you screw up the fitting, you can heat it back up and try again.  It'll just pop right back flat at the right temp.  I've painted my newest sheath, it'll be dry enough to photo in a couple of hours.

[Essexman]

I just love these kind of threads, thanks for taking the time to share with us.

[Neil]

Brilliant bit of recyling   Best I manage is using said cards for holding tape.

[jekostas]

And my update here, the finished product.  I ended up popping an extra couple eyelets in this sheath over the first.  The custom Hartsook is thicker and heavier than the Buck version, not to mention much more expensive so I wanted to make sure it would be safe.

First picture is of the two knives out of the sheaths - you can see my hanging system as well.  For the custom, I'm using a Nite-Ize #2 carabiner and some acid-brown flecked 550 cord for neck hanging.  The Buck version I'm using just some basic black cordage and a length of ball-chain necklace.  The sheath for the custom will need to dry for another 12 hours or so before I can use it, just to make sure it's well cured.  Also in the pictures are the original sheaths - you can see they're quite large.  This is the reason I was trying this - I wanted smaller, slimmer sheaths.