Ahhhh, there's the difference. You're using a vacuum bag, I built a vacuum press with pegboard as the top...I heat the kydex while it's clamped between the frame (picture a small screen window with kydex in place of the screen), then place the firearm/replica/object on the pegboard. The frame is slightly larger than the weather strip around the top of the pegboard. When kydex is soft and "droopy", I turn on the vacuum, and place the whole frame over the object. As it seals around the weather stripping, thwwaacckkk, sucks down tightly over whatever object is within the boundaries of the weatherstripping-be it firearms, knives, Hot Wheels cars, whatever you want to get a great mold of! I get great results from .06 up to .125 thickness on the kydex. This latest attempt, as it does gets sucked down, I continue the pressure from above with the foam and backing board...completely overlooked the vacuum bag! That would explain why you get good initial definition 360 degrees, and I'm just getting it on the "public" side of the holster...hmmmmm might have to try the vacuum bag route...but dang, it's a blast creating molds of the most trivial, stupid household stuff just to get practice! I really appreciate your help, and will try to get some pics up soon of some projects!