Eden, check out the two links I posted above, bro. It's the same process. If you're making dork armor outta cordovan and kydex (like, say, the ever popular Lorica Segmentata), your best bet may be to make a laminate of several pieces of thicker kydex that are glued and riveted together. Also, a quick Google search reveals:
Pitbull Armory (metal and plastic armor for "SCA," whatever that is). Given that so many people do make the stuff already, perhaps you should steal some of their ideas?