Leatherface returning as a major antagonist. Its success greenlit a prequel, released in 2006, which delved into the origins of Leatherface and of his sadistic and cannibalistic family.
In this continuity, "Leatherface" real name is Thomas Hewit , his mother Sloane dies giving birth to him on August 7, 1939 at the Blair Meat Co., a slaughterhouse where she works, and her uncaring boss leaves the infant to die in a dumpster. Luda May Hewitt finds him and takes him home to raise him. . ;The Hewitts worked at the Blair Meat Co., but after losing their jobs they switched to kidnapping people, murdering them (often by chainsaw or shotgun) and butchering their flesh, as family member Charlie claims that he got the idea from eating human flesh in the Korean War after he became a prisoner.
Leatherface in this continuity suffers from a facial disfigurement and a skin disease that caused severe deformities and tumours to his face. Due to this disfigurement, his muteness and mental retardation (carried over from the first series), other children bullied the boy. He wore a small leather mask to cover up his deformity, and worked at the same meat factory where he was born, for the same boss as his mother - the same man who had left him for dead. He also had a tendency toward self-mutilation, and a doctor diagnosed him as suffering from a type of neurodegeneration at age 12.
After health inspectors shut the factory down, Hewitt's boss and a reluctant co-worker ordered him to leave. When Hewitt didn't, the boss and the co-worker bullied him, calling him a "retard" and a "dumb animal". Acting on a long-burning rage, Hewitt killed his boss with a sledgehammer. He later discovered the chainsaw he used as a weapon after searching the now abandoned factory. When Winston Hoyt, the local sheriff, tried to apprehend him, Thomas' brother/"Uncle" Charles "Charlie" Hewitt Jr came to his aid and killed the sheriff with his own gun. Charlie later assumed the sheriff's identity.
Hewitt later made masks of human skin by slicing off the faces of his victims.
Although Leatherface's family still manipulate him in this interpretation, they do show themselves somewhat more caring for him and less abusive than in the original film. Before killing the sheriff, his brother/uncle Charlie even defends him by saying, "He's not retarded, he's misunderstood." The cruelty he suffers at the hands of his peers, inpart, inspires his murderous behavior, however it's his brother/"Uncle" Charlie who encourages his anti-social behavior and impulses.
At the climax of the remake, protagonist Erin Hardesty cuts off Leatherface's chainsaw-wielding arm with a meat cleaver, and Erin is able to escape him, though Leatherface survives the cleaver attack. Leatherface escapes after police discover his ranch house and find the remains of 33 people. The police fail to secure the crime scene properly, allowing Leatherface to attack and kill two officers. Leatherface then escapes and disappears, and the case remains open. In 2010, they discovered that Leatherface has kill 12 more people in Bowling Green, KY and made his way up to Indiana. The police are still looking out for his wherabouts.
Andrew Bryniarski, who played Leatherface in the remake, states: "In my estimation, Leatherface is like a beaten dog, he was ostracized and ridiculed, and treated harshly by his peers. The psychological damage they inflicted was immense, there's no chance for him." Terrence Evans, who played Leatherface's uncle Old Monty, says, "I think there was a chance Thomas' life could have been different. But the teasing he suffered, coupled with a bad temper, and following Hoyt around like a puppy dog, left room for Hoyt to get absolute control."
In the Alternate Ending, the SWAT team found the body that looks like Leatherface; however, Erin looked at photograph and she tells them that they got the wrong guy because they found the body had two arms; however, Leatherface had one. Also, the SWAT team just missed him. Leatherface sneaked out of the building.