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I am a hobby knifemaker, and as a result I know my way around leather from making sheaths. So, when I needed a IWB holster I just slapped one together...

Here's my problems: First: The Kydex I used for a clip (basically a J clip) snapped today after about 6 months of use. It broke clean at the top fold. I did 'adjust' the fold once and did all my work using a hot air gun. Will Kydex become brittle if overheated or folded while too cool?

Second: My wife commented that I now have brown spots on my underwear. No, not THERE, get your minds out of the gutter, on my right hip. Apparently my holster leather is leaving stains on my undershorts. I did not dye it at all. This is veggie tanned (oak) cow shoulder leather from Siegel of California. All I did was liberally work in warm beeswax and a little Mink oil to finish and waterproof it. Is there any way to stop (short of a kydex layer) the staining?

I use car waX. It Has solved that problem for me.

I can chime in on the Kydex a little. I started making things in Kydex a few months ago and have not had issues with clips breaking..yet. I read someone else had it happen but it seems more on the rare side. It does not sound like you did anything wrong first of all.

I can add that the thickness can make a difference on this issue. .6 vs .8 or .9 thickness will make a big difference, thicker is better of course. And depending on your usage could be a factor...if you are always putting pressure on it and twisting it constantly while wearing it, then you can expect a shorter lifespan.

I have had a few of my kydex clips break. It happened when I snagged them on something that was not forgiving.

The Mink oil is your problem. Mink oil really never dries out. When you heat it up by wearing the holster, it starts to flow.

Seal the leather after you stain to the color you want. Buy some clear leather sealer, Tandy carries it.

It makes a different which Kydex grade you use as well. If memory serves me the Kydex 100 if the grade used by holster makers.

"brown spots on my underwear"
...... simplest problem solution .... "go Commando", like Brittney Spears.

(Sorry, couldn't resist.)

I personally never had trouble with my Bianchi Suede IWB holster leaving spots, but never thought about it before. I used to work with leather a lot in the early 1970s, and my dad had a boot shop back in the 1940s/1950s.
Probably needs sealing, agree with/defer to the above posts.

Seal it with Fiebing's Tan Kote. Let it dry afterwards at least over night or longer.