A few years ago I carried a Leatherman Skeletool as part of my job. The pliers and screwdrivers were always useful but after I quit I swapped it for a Cold Steel Code 4. I like the utility of a larger knife but missed some of the features of the multitool. With a sheath on my belt, however, I could carry both easily.
I decided to employ my new Kydex oven and press. For this project I used 2mm Kydex sheets. It's thin enough to work with and thick enough to be durable. It's very easy to cut on a wood bandsaw or a Dremel.
I heated my cut sheet in the oven at 148C for 15 minutes to make it pliable. While it was heating, I let the neoprene foam and multitool warm on top of it. The trick to good definition is slow cooling. If the foam is already warm, the smaller temperature difference will allow it to mold for longer.
Because I wanted the Kydex molded across the entire width of the Leatherman I only used one foam pad; if you use foam on either side it would only mold half way. From top to bottom, I sandwiched a 2x6 board, foam, Kydex sheet, multitool and another 2x6. I compressed the pile with pipe clamps and let it cool for an hour.
With the plastic rigid again, I used a wood bandsaw and belt sander to trim the edges. With a drill press, I put 1/4" holes around the edges for the rivets. After that I traced the outline on vegetable tanned leather and cut it out with my folding knife. With a Crop-a-Dile I punched the holes for the rivets.
After assembling, I slit two slots in the back for my belt. It's a tight fit but after wearing it for a few days it's breaking in.
The final step was to cut the top open and the finger slit. For that I used a Dremel with a cutoff wheel. As you can see in the top picture, there's a small lip that gives a satisfying click when the tool is inserted. I also put a finger slot in it as well so I could lift it out.
The final product is a bit wide but sits relatively flat against by back. If I were to make it again I would have trimmed closer and maybe heated the edges to contour more against the body.
Having worn it for a few days I'm happy with it and it's becoming a part of my regular every day carry.