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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.CC
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.
CC