Kitbadger shows us how to reinforce the SureFire DG Switch for use with a Kydex Holster. As I’m sure you’re aware, it can get chewed up pretty badly from abrasion caused by the holster.
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This is the same way SF warranty repairs damaged switches, but it’s treating the symptom rather than the problem – the added thickness only exacerbates the problem. What you should do instead is fix your holster with a heat gun and a screwdriver or any other redneck prying tool. It’s no less bubba than heatshrink, but you’ll only have to do it once.
Don’t think you’re out of the woods if you bought one of the very few Safariland models that claims it accomodates the DG switch. 9 times outta 10 the switch still catches on the holster lip, and when a DG switch fails it almost always fails “on” and you can’t turn your light off. If you carry for work I strongly recommend you keep the original switch piece in your kit bag just in case.
SureFire does have a lifetime warranty, so while it’s a pain in the ass. If you get an RMA, SureFire will either repair or replace your switch.
Sanded down my Safariland 7TS. On the older ALS/SLS I heated them up with a hair dryer and then folded up some hardstock and holstered the gun with the cardstock under the trigger guard to create the space needed for the DG.