Kydex Holsters Tutorial

To make a Kydex holster:

Step 1. Get two pieces of plywood about 1 foot square and about 3/4 of an inch thick. Obviously, the more flat the better. Home Depot type stores normally carry pre-cut lumber in small sizes.

Step 2. Go to K-mart or Wal Mart and buy a foam sleeping bag pad. Normally they are blue in color and much cheaper than what you can find at a knife maker supplier.

Step 3. Glue a foot square piece of padding on each of the two pieces of plywood. You may double up on the thickness to give a more molded look, but well require more final adjustment as it will be a SUPER tight fit.

Step 4. Get a old toster oven or a heat gun, or even your home oven and turn the heat to 225 degrees to start and see what happens. Increase the heat up until the plastic becomes pliable. The heat will be around 265 degrees for most but it is common to get it up to 300 degrees. Heat guns are easy to control and for that reason popular.

Step 5. Wearing welder's gloves, fold the Kydex over the gun on the foam pad, leaving a bit of space at the fold for a sight channel plus plenty on the frame side for fine trimming and fasteners, then put the second plywood & foam board over the kydex. Try not to conserve too much or you may find yourself short when trimming later. To get a more rounded, professional looking sight channel, you can use a wood dowel. Cut it to fit from the front of the rear sight the length of the slide, notching it to go over the front sight. Use a piece of tape rolled up sticky side out to hold it in place.

Step 6. Stand on the plywood, foam, Kydex, gun sandwich for 5 minutes. Or you can use 4 of the Quick Clamps allow you to quickly adjust the pressure (Home Depot has these). The more pressure, the better as it forces the Kydex to mold more, just insure it is even pressure. There are some folks out there that actually backed the car up on the boards!

Step 7. Get off of the sandwich. Let cool for a few more minutes, 5 or so should be fine.

Step 8. Fit will be pretty tight. Use heat gun to loosen up the fit to your pleasure. You may also wish to use some thick walled surgerical tubing as spacers for the tension adjustments.

Step 9. Trim to shape with handsaw, bandsaw or Dremel tool. BEFORE cutting, I HIGHLY recommend using a grease type pencil to mark cut lines to insure what you cut off is what you actually wanted to. Round the edges for a more finished, professional look and to avoid undo damage to pistol finish.

Step 10. Put a few Super Glue drops on the joint where needed to seal in place. Skip this step if you will be using multiple (2 or more) tension adjustment points.

Step 11. Drill 1/4 inch holes and install eyelets or Chicago screws. Eyelets are used for either non-tension adjustable (Super Glue method)or to keep the screws from causing eventual damage to the Kydex.

Step 12. Install a belt loop of your choice. Either buy a Tec Lok for $9 or form your own belt loop by the above method. If you intend to use Tec Lok, you need it to serve as a template for the eyelets.

**Side note 1: You can actually build the bottom plywood into a box by adding sides and making the top fit somewhat tightly to avoid slippage during pressing. My mind's eye tells me this could happen, exspecially using the Stand On It method.**

**Side note 2: Depending on the actual pistol you are using, you may find that having a flat enough mount area is difficult. You should be able to resolve this by using a small flat piece of wood (1/4"x2"x2" is plenty)positioned roughly where you wish the mount point to be before pressing. Adjusting where this piece lays will adjust how high your holster will ride. (Step 6). 1/4" will give you a recessed mount, so 1/8" thick may be more desirable, depending on how close to the body you want the holster to hug.**

**Side note 3: Some may wish to leave a tab during the cutting process to make a belt loop. Make sure you leave it long enough for a fold under that will attach to the lower porition of the holster via Chicago screws. 4" should be enough for a 1 1/2" to 1 3/4" belt depending on where your mount point is located. Use a 3/8" - 1/2" by 1 1/2" board to wrap the fold under after heating. Then heat it at the top bend area and fold back and down to your holster mount point. Drill 2 to 3 holes straight through the belt slide, the fold under and REAR ONLY of holster to pass the "nut" porition of the screw set. Ream the holes a bit larger then the Chicago screw heads on the rear of the belt slide, install screws and done!**

**Side note 4: Some pistols will require cardboard spacers during the molding process. For instance, EAA Witness has a largish safety which after molding could cause drawing issues by hanging itself up on the holster. To resolve this, a strip or two of cardboard the width of the slide flat and the length of the slide can be taped on to create a side channel.

**Side note 5: Obviously, this method can be used to also create mag holders along the lines of the Comp-Tac's by merely leave a fold over piece when doing layout and again at final cut out, use a heat gun to soften the bend area and bend back to create the belt tab. Then notch the base and heat and fold in to create a closed bottom. Double holders may be more difficult but I have some ideas in mind and will experiment to see if they are viable solutions.**

You can buy Kydex from a knife makers supply house for 6 bucks a square foot. Some locations may be cheaper so shop around on the internet. Most plastic distributors will sell you 4 by 8 sheets with a minimum order of 12 or if lucky, and a very small distributor, in 2 or 3 sheet lots. Try : http://www.knifekits.com/store/s-pages/kk_store_1mainframe.htm?kk_products_sheath_main.htm~smain for starters as they list everything from the Kydex to a mold press for it.

This is a work in progress as I have been discovering new and different ways of doing things. Hopefully, I can include some pictures in the near future.

_________________
XD40 Service w/DGR&22lb spring, extended mag release,Springer Precision 3lb trigger, polished ramp/hood & painted sights.
XD40 SubCompact Bi-Tone w/ extended mag release, polished ramp/hood & painted sights.

Multiple Non-XD type stuff...

Last edited by TxStorm on Sat Jul 01, 2006 11:56 pm; edited 4 times in total

Thanks for the info I'm going to order some kydex and try making a speed holster. Laughing

Great post, Trace!!!!

_________________
XD 9mm Sub Compact
Canyon Creek trigger job, Skateboard tape grip-surround, Pearce grip extensions

XD 9mm Tactical
Canyon Creek trigger job, polished feed ramp & bbl, Don's guiderod & 16# recoil spring, Hogue grip sleeve, Magwell & frame plug, 5 mags with bump pads

	XD_Dan wrote:
	Great post, Trace!!!!

Thanks!

Meant to make before I left but I forgot and it needed a bit more refinement. On the website listed above they also sell a DVD 1 hr long on this too. Think I may order it tomorrow with my Kydex sheets, EMT Red looks kicking and easy to pick out if I forget who I loan what to. Twisted Evil

_________________
XD40 Service w/DGR&22lb spring, extended mag release,Springer Precision 3lb trigger, polished ramp/hood & painted sights.
XD40 SubCompact Bi-Tone w/ extended mag release, polished ramp/hood & painted sights.

Multiple Non-XD type stuff...

Awesome post.

Any pics of the final product?

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XD9 Service, CC Trigger, DGR, TFOs, KG Gunkote

i have the dvd...the instruction posted above are better than the dvd. unless you just have to see it prior to trying it out.

LJ,

I have a fresh order in for some more Kydex and other materials and intend on doing some step-by-step type photos including a finished holster. Will be also making a single mag pouch for an XD mag photo set. I am going use EMT Red colored Kydex for both so it stands out better. Hmmm.. best get some fresh batteries for the camera while I'm at it!

_________________
XD40 Service w/DGR&22lb spring, extended mag release,Springer Precision 3lb trigger, polished ramp/hood & painted sights.
XD40 SubCompact Bi-Tone w/ extended mag release, polished ramp/hood & painted sights.

Multiple Non-XD type stuff...

where do you get your kydex.... once company online wanted to charge me an extra 15 bucks because my order wasnt $50.00 or more....

_________________
XD9 service Bitone / XD45ACP service Black
Kimber Eclipse Ultra II
S&W model of 1899,M&P,38 terrier,10,17,19,19K-Comp, 27,29,57,65,66,342,547,625,629x2,646,686x3,696,940
NAA mini revolver
KelTec Sub 2000
Bushmaster AR15 M4
Winchester 1300 Defender

Dont cry because its over, Laugh because it happened.

I have not used them but they do have the .080 sheets and no minimum order. Shipping is like $8.

http://www.knifekits.com/kk_1mainframe.htm

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JW
Houston

Hey.. I was too quick on the 'Enter' key.

This guy in in Houston and has a location by my office!

http://www.texasknife.com/

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JW
Houston

I can get it for $10 shipped to me

Kydex T Sheet 1/8" Thick, 12" X 12" Sheet, Black

	Qballwill wrote:
	where do you get your kydex.... once company online wanted to charge me an extra 15 bucks because my order wasnt $50.00 or more....

Knifekits.com is what I used and just placed another order today, shipping was $7 and ordered just enough for 4 holsters and a few mag pouches. Now that SG's ex- EAA Witness is here, I'm gonna do one in a Cen-Dex NightHawk style for USPSA use. Link is also in the orginal post around the last paragraph. I like them better than the one SG mentioned as they have about 8 or 9 color choices and 2 sheet sizes, 12"x12" and a 12"x24". It also comes in 2 thickness' and you can also get your Chicago screws/rivets and 3 different premade belt attachments, including a tec-loc (in 2 different sizes). The online selection at texaskinfe just didn't look as large and I'll be paying shipping either way. KnifeKits is a tad lower cost too.

_________________
XD40 Service w/DGR&22lb spring, extended mag release,Springer Precision 3lb trigger, polished ramp/hood & painted sights.
XD40 SubCompact Bi-Tone w/ extended mag release, polished ramp/hood & painted sights.

Multiple Non-XD type stuff...

Just ordered 3 12x12 sheets for $11.40 plus $6.50 shipping.

http://www.northcoastknives.com/northcoast_knives_Supplies3.htm

	htown'sDad wrote:
	Just ordered 3 12x12 sheets for $11.40 plus $6.50 shipping. http://www.northcoastknives.com/northcoast_knives_Supplies3.htm

Not to start trouble, but that is .06 thick and is a tad thin for holsters, great for knife sheaths. Pretty much around the 'thin" of the FIST line of Kydex holsters. Some of the posts I've read during my research stated tearing issues during heavy use, like shooting a match. One poster stated his tore with a loaded weapon after the make ready command at the belt loop area. I personally haven't tried .06, mind you, just basing my avoidance on my research.

_________________
XD40 Service w/DGR&22lb spring, extended mag release,Springer Precision 3lb trigger, polished ramp/hood & painted sights.
XD40 SubCompact Bi-Tone w/ extended mag release, polished ramp/hood & painted sights.

Multiple Non-XD type stuff...

Thanks for the info. Guess I'll just play with this batch do mag holders and other small stuff like a holster for my charterarms offduty. Maybe an AR mag holder and 12ga ammo holder for my three gun.

TxStorm.. I know I just sent you a PM on this.. but what about doing a suede liner for the holster like Safariland does with the 5186.. any thoughts?

Also, I'm digging this carbon fiber finish Kydex from the place you suggested.

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JW
Houston

.06 is fine, it is opretty damn thin though. it holds shape but you can push it around a lot easier than you can .08. it is also a lot easier to work with than .08. however, .08 is ideal for holsters. i made a pocket holster for a snub nose today out of .06 and it is good for that application. .06 would be great for a IWB , for an OWB though, .08 would probably hold up to more force.

	SpaceGhost wrote:
	TxStorm.. I know I just sent you a PM on this.. but what about doing a suede liner for the holster like Safariland does with the 5186.. any thoughts?

I was looking into the suede liner too. What would you use to glue the liner? When do you glue the liner during the forming process? Just thinking outloud.

	SpaceGhost wrote:
	TxStorm.. I know I just sent you a PM on this.. but what about doing a suede liner for the holster like Safariland does with the 5186.. any thoughts?

Biggest thing I see is getting it to stick before heating and then I can imagine a few forming issues along the lines of bubbling etc. Unless one could reheat the spine after forming.. spread the holster open then lay out the liner. That's on a fold over style. On a "pancake" style where you use 2 separate sheets of Kydex for molding, i.e G-Code holsters, It would be easier to do the in lay of the liner, maybe spray glue, come back with some leather working tools to sew up the outer edges to increase lifespan. Maybe heat a threading chisel to get through the Kydex, a bit time consuming..Possible .. now I'm plotting.. Twisted Evil

Definately want to try it on a .08 thickness, I think .095 and up would make things harder than they should be. See? Talked myself into it, didn't I?

Edit: Maybe a boot maker type machine designed for heavy leather could be used to sew the outer edges. Well, at least the voices in my head say it sounds pausable. Wink

_________________
XD40 Service w/DGR&22lb spring, extended mag release,Springer Precision 3lb trigger, polished ramp/hood & painted sights.
XD40 SubCompact Bi-Tone w/ extended mag release, polished ramp/hood & painted sights.

Multiple Non-XD type stuff...

I'm digging the carbon fiber too! Twisted Evil

_________________
XD 9mm Sub Compact
Canyon Creek trigger job, Skateboard tape grip-surround, Pearce grip extensions

XD 9mm Tactical
Canyon Creek trigger job, polished feed ramp & bbl, Don's guiderod & 16# recoil spring, Hogue grip sleeve, Magwell & frame plug, 5 mags with bump pads