A kydex sheath is the same process as a holster with a simpler object: heat the sheet, press it over the tool, trim, finish, rivet, clip. A multitool is easier than a pistol because it is a box with no trigger guard, and harder because the retention has to come from the tool's own shape, which on a smooth folded Leatherman means the mold has to be exact. This guide walks through making one, and where the difficulty actually is.
What you need
.080-inch kydex, a foam press, a heat gun or toaster oven, the tool, a saw, a belt sander, a drill, eyelets and a press, and a clip. About $150 in tools if you have none of them.
Steps
- Decide the style. A taco (one sheet folded around the tool, open on one side) is easiest and slimmest. A two-piece (two molded halves riveted together) gives more retention control.
- Cut a blank two inches larger than the tool all around; double that for a taco.
- Heat to 300°F until limp and glossy.
- Press. Tool on the foam, kydex over, close and clamp. For a multitool, orient it so the press catches the plier head or the handle edges; that is where the retention will come from.
- Cool in the press, five to ten minutes.
- Trim to the outline. Leave enough above the tool to grab, and enough kydex to hold a clip.
- Finish the edges on the sander and round them.
- Drill and rivet the seam with eyelets. Add one or two retention screws through the seam so you can adjust how hard it holds.
- Clip. Bolt on a belt clip or a Tek-Lok through the eyelets.
Where it goes wrong
Retention. A Leatherman is a smooth rectangle, and a mold that is a little loose holds it by nothing. The tool has to be pressed hard enough that the kydex wraps the edges of the handles and the plier head, and the retention screws have to be able to tighten the seam. It takes a few tries.
What ours are
Every Clip & Carry sheath and holster is molded from .08-inch kydex, handmade in the U.S.A. by military veterans, with adjustable retention and a lifetime guarantee. Each sheath is molded to one tool with adjustable retention and an audible click, from the Wave to the Skeletool, with interchangeable belt, Tek-Lok and MOLLE clips. See the sheath collection.
Frequently asked questions
Taco or two-piece for a multitool?
Taco for slimness, two-piece for adjustable retention.
How do I get it to click?
Press hard enough that the kydex wraps the handle edges and plier head, and add retention screws through the seam.
Can I make a sheath for a knife the same way?
Yes. A fixed blade is easier; the guard and handle give retention.
What clip do I use?
A belt clip through the eyelets, or a Tek-Lok for a thick belt.
Is kydex better than the nylon pouch that came with the tool?
Yes: one-hand draw, no flap, no moisture, no wear.
The bottom line
Heat, press hard, trim, finish, rivet, clip. Retention is the hard part. Or buy one that already clicks, molded to your tool.
Related reading
How to cut, heat and mold kydex
How to make a kydex holster
Kydex vs nylon multitool sheaths
