Leatherman case too big....
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See if you can find an old fashioned shoe maker or holster maker to make you a new one to fit.... or check on Ebay and see if you can get a custom one made from a craftsman there.... another thing to investigate... you can find the materials at Tandy Leather Co. (at a store or online) .. it can be hand laced or sewn... so you would not need a special sewing machine.. (we have gotten several holster kits there... and with a little practice.. they turn out fine)
Did you try Leatherman.com? I had to Google it to see what it was 😓 and I found this site. If they originally made your old one, surely they would have a solution for you. This is their 800 #:
1-800-847-8665
Good luck!
If you have an old leather belt that would be of a thickness to snug up the extra space, you could cut it to size and use a leather glue to attach it to the inside. Just a thought :).
Or you can look for leather kits and make one yourself