tom, found another interesting post on the cpf, there is a shop in texas i think that sells kydex by the sqft, i think off the top of my head it was $4.50 for 1sqft, and $6 for 2sqft, just heat with a hot air gun and away you go, i'll have a look and try and link it all up, here let see if this works!
all the best steve


oh just found the site, its on the second page, www.texasknife.com