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Try locating some kydex.  It's the plastic that a lot of knife sheath's are made of.  It cuts easily and can be sanded on the edges to the shape that you want.  It also can be heated with a heat gun and bent to shape, or even molded.  I used to make the entire sheath's out of it before I got all of my leather working materials to make leather sheaths with.  I picked up some 2'X4' sheets from a plastics wholesaler for $2.00 each.  They were the left overs from larger sheets and they were glad to get rid of them.  Try the yellow pages if you have a large city nearby.


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