Need some advice from people who have "been there, done that" with Kydex projects.
I have decided to try my hand at creating some high-ride, OWB, pancake Kydex holsters (picture a cross between a Rusty Sherrick High Ride and a RCS Phantom). I have researched the process, obtained all the materials, made my templates, and am getting ready to dive in, but I need some advice on a few issues since this is all brand new to me...
1. Regarding the heating/molding part of the procedure, which of the following will give me the best results:
a) Cut Kydex templates slightly oversized, heat, mold in press, rivet, THEN trim to final dimensions.
b) Cut Kydex templates to final dimensions, try really hard to keep everything aligned during the molding process (seems like this might be difficult unless the heated Kydex is "stickier" than I envision), rivet.
c) Cut Kydex templates to final dimensions, sandwich sides together and place outside rivets, put a thin piece of sheet metal inside to keep the sides from sticking together (or is this necessary?), heat, carefully open and slide handgun in, mold in press, place remaining rivets.
2. Do I need to use any adhesive like contact cement or will the rivets be sufficient? The area I'm specifically concerned about is the belt slots.
3. Regarding cutting the Kydex, I'm thinking long straight cuts will get the utility knife, curves/details the jigsaw, edges fine grit sandpaper, and corners the Dremel on low speed. Good plan or not? Suggestions?
Thanks for any advice you can give.