4 suggestions!
-Try alchemyarms.com.
http://www.alchemyarms.com/product_p/al ... it-002.htmIt is (was?) run by a member here "Honcho". While his last login here looks to be 3 years ago, I see the website is still up and running. I worked with him some years back to get my own night raider casted up. The site still lists what I know to be excellent quality resin casts along with patches, VP70s and Service C shirts (be sure to check page 2 of the Aliens section). Only drawback is they are definitely NOT flexible and probably wouldn't be con safe without grinding down the point/edge.
-Another option for a con-safe knife is to remove the blade and replace it with...well anything. I did that here with a "Wilderness II" (same handle, so when I heated and popped the blade out, no one would be the wiser when paired with an accurate sheath).
viewtopic.php?f=3&t=16359&hilit=con+safe+raider-The third option is Spat, with a catch. He has added a flexible 'explorer' knife in-sheath as a "Hicks knife" to his product list. It appears he decided to cast one of the above Wilderness II in its sheath as a single unit. It is the correct handle, but the sheath is all wrong and is bulkier than the correct one (as a result of having a wider blade on the wilderness II, plus a sharpening stone pouch not present on screen sheaths). Seems like a nice unit that is def con-safe, but not correct/accurate sheath overall.
-Finally, I've done this in a pinch with my Explorer MM-IV hudson knife. Cast your own from materials around the house.
Step 1- find some "Silicone 1" caulk from the hardware store. Color/brand doesn't matter but it MUST say "Silicone 1" on the tube. If it says "100% Silicone" or "Silicone 2", this will not work. Look for that "1".
Step 2- Squirt into bowl along with lots of water and a generous portion of dish soap.
Step 3- Kneed with your hands and mix into the dishsoap water until you feel it start to get firm. The INSTANT you feel it firm up, slap it down on a table or in a box and press your knife into it and roll that handle up in silicon.
Step 4- It will be dry in probably 20 mins. Either pull with force or cut out your object. The details are unlikely to be super crisp with this method and water pockets/drops may leave imperfectios, but it will give you a mold for ~$7 to pour whatever you want into.