Smitty,
I molded it in a homemade press I built out of ply wood and a foam sleepind pad (found at 
www.northcoastknives.com) as noted by Stretch.  I heated the material up in the oven, wrapped the blade and had my son stand on it while I clamped it down.
WestEndMike,
As far as the scabbard having issues, that is solely my opinion.  I did not have the correct materials on hand to mold the belt loop, and I did not leave enough material for the loop, although it worked out.  It is a left handed carry, although I originally wanted a right handed carry.  I am actually glad now, as I am a right handed shooter, and that would be just too much weight on my right side.
I did grind down the ring.  That took the most time, besides sharpening.  I posted pictures of just the knife in my other thread:  
My original Khukri thread As far as making them for the forum members, I would be happy to lend a hand to anyone who wants it, just dont expect a quick turnaround, I have a newborn coming any day now!
Old Bald Guy,
I was nervous at first too, but now I feel a lot better.  I have another plan in mind for my PSK.  I will post pics of that when I get it done.  Just remember to be patient.  I am terrible with patience, and that caused me a few issues during this project.
Stretch, 
Thanks for reminding me about the link!  I found the design for my press there!  Good luck with your project.  I hope you have as much fun as I did!
Garrett