forget knifekits and texas knife.
the knife making supply companies buy items like this and charge a premium, just like the "gunsmithing" companies that sell simple tools like files and drill bits for way higher prices than what the you would pay from suppliers of the industry that uses them regularly.
interstateplastics dot com
this is the place to get the kydex, have them cut it to 1'X1' squares to drop the shipping way down. i use the .060" for sheaths, and the .093" for belt clips, it would probably work well for holsters too. i like the thinner stuff because it molds easier and shows a better impression, but when working with a a gun you have a thicker piece with way more definition, so it should show off the impression nicely.
fastener-supply dot com
check out the eyelets, stimpson GS. the sizing is in 32nd of an inch. so a 6/6 is a 6/32 diameter 6/32 long (3/16x3/16)
the diameter is a preference, unless you want to use chicago screws, then you need to go with 1/4" or the #8 diameter. if you're using the .060" material you want to use the #6 length eyelets, and for the .093" material use the #8 length eyelets
they have a few different finishes for the eyelets, get the black oxide if it's available at the time. you're going to want to buy some birchwood and casey brass black for touching up the eyelets, sometimes the black wears off when you're crimping them on
also get the corresponding die set to crimp the eyelets on. don't get talking in to a fancy press or anything for the dies, drill a hole the diameter of the die shank in a piece of wood, and use that to hold the bottom die, the top die sits in the chuck of your drill press, no point in buying another tool when the drill press works perfect for it.
use a large toaster oven for heating the kydex too. play with the temp, i find my oven set at a little over 300 works beautifully.
for molding kydex, look on amazon for a camo hunting cushion. one of the hunting cushions thats a seat and back held together with straps
most of the foam you find out there stinks, it doesn't hold up, and gets cut up by the kydex, ruining it permanently. these cushions can be found for about 5 bucks at dickssportinggoods after hunting season.
cut them in to suitable sizes and glue them to some scrap corian or wood as a backing. the thin layer of cammo material will protect the foam from getting damaged, but is thin enough not to effect the definition of the mold
the last piece i had like that lasted well over year. that's a long life for kydex molding foam
you can make a press or buy a press, but if you have a vise in the shop you can use that too. the presses are over rated.
tin snips work well for cutting the kydex, i use a bandsaw. then once molded i refine the shape with a 2X72 belt sander, but that can be done with just about any sander.
i can't think of anything else right now. shoot me an email if you have questions.
Spanglercustomknives@gmail dot com
spanglercustomknives dot com
sorry for the links, i guess i'm too new to post links