Hey, I lost the thread of the replies, but heavily tooled leather armor is sort of my jam, so in response to your first post:
No no no, you have to tool your leather BEFORE you shape it! Trying to put detailed tooling on leather that isn't perfectly flat is a nightmare. I mean, I've done it, after I did a whole piece and then decided that it needed more jazz (see the first picture -- originally it had only the dragon in the center and the border along the edges), so I took it apart and got it wet again, but it's not going to lie flat after you've already put curves in it, and it's so, so much easier just to do your tooling beforehand.
The second set of pictures is for a pair of elbowpads (Isabela's from Dragon Age 2, if you've ever played it), and you can see the steps -- do your tooling and finishing (edge beveling, punch any necessary holes, etc) before you shape it. The design does get slightly distorted when you put a curve on the leather, but it's never actually caused problems for me.
As for waxing, boiling, baking, etc -- honestly, I don't think it's necessary. 10 oz leather is plenty hard, especially after it's been wet-molded, so doing anything else to it is just "More Historically Accurate Than Thou" wankery, in my opinion. Both boiling and baking are touchy procedures; get the timing/temperature wrong and you run the risk of ruining your project on the very last step, and winding up with a mass of shriveled brittle garbage. Waxing is fun and much less dangerous (I wrote about it here: http://armory-rasa.tumblr.com/post/136427185638/thrall-cosplay-how-to-make-wax-hardened-leather) and you certainly don't need to dip your leather pieces, a disposable paintbrush and a hairdryer will do you fine. It's good for making pieces waterproof, and it does make them quite hard (as long as you're not wearing it anywhere warm :P), but unless you (or your customers) are going to be LARPing in the rain for days on end, again, I don't think the extra step of waxing is worth the time it takes.
(Full disclosure, I sell to the cosplay crowd, not the SCA crowd, so there's less demand for historically-accurate methods and being able to withstand the elements -- but it's more that the pieces wouldn't look so pretty after combat, not that they wouldn't be able to perform.)
But yeah, anyway. Do your tooling first, while all the pieces are flat. Don't even try doing it on an anvil after you've shaped the leather, it will just end in table-flipping rage.