[Bill Harsey]

This thread is about forming kydex.
I'm not sure where to start so here is the first simple thing I thought of to try and make things easier.
When one is forming kydex in a press around a blade, there has to be some relief between the blade and the Kydex or else the blade will pinch going in and out of the finished sheath.
Many years ago I was shown by Bob Terzoula how to put tape on the blade until we have something like thirty or so thousands of an inch thickness before placing the blade and handle in the press for forming the Kydex.
If your interested in thickness's and want to put the micrometer on some tape, fold one short length of tape over and then measure the thickness with the micrometer. This keeps the "mike" from sticking to the tape. Divide that reading in half and you know the thickness of each layer of the tape used.
Or just use four or five layers of good quality blue masking tape. It comes off easier. Place tape straight up and down the blade, not around.
Using a sharp hobby knife, trim the edges of the tape right next to the edge and spine of the blade. This way the tape doesn't "print" through the kydex and show on the outside.
I have never placed tape on the handle.

Handling sharp things can be hazardous to your band-aid supply!
Especially when removing tape from sharp edges. This is not theory. Work slow and with care removing tape.