The belt loop on the nylon belt case for my leatherman blast bit the dust a while back & it ended up stashed in a drawer. I got tired of missing it at my side so I thought I'd take a stab at some freehand kydex bending. I don't have the shop set up here at the new house, so I tried to simplify the design as much as possible & do a complete job just cutting and bending - no rivets or glue.
I started with a paper template
which got transferred to some .060 kydex and cut out. All the bends (except one) are just straight lines. I ended up using a butane soldering iron with the tip removed. It has a catalytic combuster, so there is no flame coming from the end - just hot air.
I just played the hot spot back & forth over the line of the bend I wanted to make until it was soft enough to shape. Rolling the tube shape for the flashlight would have been easier with a real heat gun ... but I managed OK.
Here is the result. So far it's been working fine - good retension, but easy removal & replacement.
Nick