I decided a few weeks ago to start making my own kydex. I bought a toaster oven, dremel tool, coping saw, a bunch of kydex, and a die set for the eyelets. I need a belt sander and a bench vice, but it can be done by hand. The first few tries were a disaster, but I finally got it right on my fourth or fifth attempt
For size reference, here's the Bravo 1 in my hand:
Here's the front of the sheath (I made it to wear on my left hip, so the "clean" side of the eyelets faces that way, but it will work either way):
Here's the other side, with a Teklok:
The sheath is loose around the blade (wrapped it in a few layers of tape when molding the kydex, important because if dirt or anything gets inside the sheath, the hard kydex will press it into the blade and scratch the hell out of it) but very tight around the handle:
Doing this myself has given me a lot of respect for the guys who do it right consistently, you really have to do each step in the right order, and perfect, or you end up with a ruined sheath. There's also quite a bit of "art" involved to get it right.