I want to make a thin back pocket sheath for the 4" KNIPEX pliers to keep them from putting holes in my pocket. My idea is to make it just a bit smaller than the pocket but form fitted for the pliers. I assume you would take 2 sheets and heat them somehow and form over the pliers? Would that work or is there a better way? Is this DIY'able?
1. How do you shape/form over pliers?
2. Do the 2 sheets just melt together or is there a way to "weld" the edges.
3. What thickness Kydex? Looks like 0.028" is the thinnest you can get?

Pic of the KNIPEX pliers for ref.

If I recall correctly heat gun and Chicago screws.

I've made my own holsters before. You don't need exactly this kit but it will give you an idea of what's required. https://www.amazon.com/Kydex-Holster-Making-Thermoform-Tools/dp/B0BMS92WTM?th=1

Heat the kydex up with a heatgun or in the oven until it's malleable. Inside of that press is Molding Foam.


You put your two sheets of kydex (or a single piece folded over) with the tool in the middle inside of the foam and clamp the press shut until it fully cools. Pull it out, put some of the rivets/eyelets in a few places around to keep it together. Trim the kydex until it's in the shape you want. Use the heat gun to loosen up or tighten the holster so that it holds the proper tension.

The only tricky thing is that if there are any parts of your tool that stick out more than the area above it you'll need to make some type of channel so you can pull it out. For example, the sights on a pistol or other protruding pieces you'd tape a dowel rod to so the sights aren't locked in there:



I already had a heat gun so I just had to purchase the foam, rivet set, rivets/eyes and kydex. Was about $50. Made my own press with 2x4's and clamps.

Great info thanks.