1. Summarize the process of completing a retention device.
A. Creating a press- With any level of experience working with your hands and a basic understanding of some simple tools anyone could make a Kydex Press. I think the two most important parts of this process the hinges you choose and the foam material used to actually press the Kydex to the object. Hinges that are too small and made for something like a jeweler box will not last long because of the amount of pressure it takes to get a good press and cheap foam may melt to the warm Kydex or be worn out after just a few uses.
B. Planning your design- For some, planning your design may take two full days to get just right with exact dimensions listed Etc. I would work like this a long time ago and I found one major flaw with this type of design process and that is the expectations vs reality. Making a quick sketch and taking the extra time to prep everything every time works best for me now. I may misalign the Kydex during the press or miss a spot when drilling my holes for rivets and this results in an imperfect product. We are human and thus prone to error. In most cases it becomes how can I save this rather than the expectation of perfection.
C. Constructing your mold- When making the Mold or prepping the item that is going to be pressed, it is important to think this step out. Areas like the ejection port and the section in front of the trigger need to be filled in to avoid over pressing and creating undercuts that make it more difficult to use the holster. When making a taco style, one piece holster, it is important to create a channel your pistols front sight can slide in and out of. Finally, block the area you think you will mount your belt hook to and If the firearm has things like bulky tac lights or lasers attached to them, you will need to block the item out so the holster has a channel for things like that to slide in and out of as well.
D. Pressing and heating your design- The process of heating and pressing the Kydex moves really fast. In most cases the Kydex material can get to the correct temp in just a couple minutes and once malleable, will only give you half that in workable time before it begins to cool off and become unusable. On average I will heat the Kydex to anything from 305-345 because any hotter then that and the material will begin to miss shape and melt to the tray I use to heat. Lastly, unless you are used to handling hot things bare handed, use some gloves when handling the heated Kydex. This not only protects but allows for a more controlled press of the material.
E. Finishing procedures- The finishing procedure has got to be my favorite part of this whole process. This is the step where everything starts to take shape and you begin to see the finished product. Depending on what tools you have on hand this step can also be the most tedious. If using a hack saw to trim material and sanding by hand to clean up your edges, this step may be your least favorite. However, If using a scroll saw to trim and a belt sander to clean up your edges then you are finished in a few short minutes and usually have a cleaner looking finished product.
2. What was the most challenging part of this process, and why? What will you do differently next time to mitigate that challenge?
If I was asked what I thought the most challenging part of this process was I would have to say it was the design portion. One mistake in your design has ripple effects in your finished product. Forgetting to block off a section where you would be attaching belt clips could result in mounting screws scratching the firearm or magazine every time it is drawn. I really want to knock out a quick design so as to not over think the process but in reality, this is the one step where you need to stop and think out all the tiny details.
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