I purchased a fairly decent kukri recently,a working camp tool, not some expensive custom blade, the knife blade is decent,the handle will be replaced, but the scabbard is basically cheap crap and while I could send it out to have a kydex sheath made custom, Im rather reluctant to send the knife out, and would rather fabricate the sheath to my specs so any info or experience is welcome.
price is not the big issue as they are cheap enough, but Id like to make it myself.

http://nepalkukri.com/index.php/popular-products/11-afghan-brown.html
custom kydex scabards / Sheath's are available, from several suppliers, or you can get the materials to make your own.
http://www.knifekits.com/vcom/index.php
http://www.valhallacustomkydex.com/knife-sheaths.html
http://willowhavenoutdoor.com/general-survival/the-1-hour-custom-kydex-knife-sheath-in-your-kitchen/
http://clevelandkydex.com/index.php?main_page=index&cPath=28_4

Little bit of a pain just to make one sheath, but if you want to, the key will be to buy a hand setter for the rivets/eyelets. In order to set them properly, that would be the minimum you'd want to get. As for the rest you can probably do the heating with a toaster oven and/or your kitchen oven or something similar as long as you're careful and follow some guide(s) from the internet. You can probably press it with a towel and a couple of 2x6's if you find the right examples on the web on how to make yourself a simple press. Be sure to form it quickly as it cools fast and sets up really quickly. Good luck with it.

thanks for the info so far! if anyone else has experience please chime in!

I've done a few. it isn't too tough, but I could never get the rivets right until I bought the press.

Rivets are the killer. I use the hand setter and some end up looking like they've been chewed on... I'll get a rivet press before I do another.

Toad that's very nice looking work. What are you pressing it with? I'd love to be able to do that

I bought some of the foam from one of the knife making supply web sights and made a press. the amount of spring retention can be controlled and adjusted later if necessary.

another thing I found out the hard way is to NOT EVER use a belt sander or sand paper on the Kydex, unless you can scrub the inside of the sheath/holster. if you get one tiny grain of sand in there, it will scratch the knife every time you use it and it will never go away. I use files or rasps for final shaping.

Wow that's an excellent tip I never thought of...thanks for posting this...

a little tip I have figured out. 2 layers of masking tape on each side of the blade only while pressing gives it just enough clearance that the blade does not drag when going in and out. The dies for a press will make all the differance in the world. however if you have a drill press, chuck a 3/8 drill bit, scoot the table to the side a little and drill a hole in the table, chuck up the top die and drop the bottom die in the hole and instant rivet press.

that little tip would have saved me ~$70

I'll send you a bill. Say half. LOL