Saddle Shop Life

My Leather Floral Tooling Process

When it comes to actually stamping out the floral design, every leather tooler is different in their approach.  To me, the main thing that sets a productive tooler apart from the competition is all in their process.  As with any goal or project, the main thing to focus on is devising a plan and executing the plan with great focus and uninturupted deligence.  This is almost impossible if you are taking time to decide which tool to use next, or worse yet trying to find the tool you need next.  I am a firm believer that any task or project involves a certain set of rules and a certain workflow that, once decided upon and followed, lead to high productivity and a cleaner product when completed.  Each and every product has a certain workflow that works best for the environment and the craftsman making the product.  The following is the workflow that I use when tooling the majority of my patterns.

When I begin any floral tooling job, and once my artwork is designed and carved in, I begin with under cutting all small curves within the pattern.  I make it a point, anytime I pick up a tool, to go through the entire pattern performing that tool’s task anywhere I can before putting it down and grabbing another tool. This rule holds true no matter the size of the tooling pattern.  If you will get into this habit then your overall tooling time will decrease greatly.  A lot of time is wasted switching tools or like i said before… searching for the tool you need.  If you have it in your hand, do all you can with it before moving to the next one.  Tooling is about focus, and staying focused on the tasks lead to a completed piece of art.

With under cutting, I recommend having a small, medium and large in order to be able to take care of virtually any size tight curve.  Undercuts are great and keep you from trying to fit a square beveler into a curved line.  I work my way up from small to large when it comes to tool order when undercutting.

After all the undercutting is completed, I move to my crowners.  This is not a tool that is mandatory, but I find them to be a great time saver and they keep my scalloped rounded and clean.  These work much better than beveling around them with a tiny beveler.  These are a one tap tool for the most part and I keep a small and large, these two sizes will handle most any scallop that I need.  I will also use the large one on the tips of any vinework that has its tips exposed and not under a border or other vine.

When all this is complete, I now move on to my beveling.  I use a small, medium and large checkered beveler and I run them from large to small.  I first bevel all the long lines with my largest beveler going through the pattern to bevel as much as I can with this tool.  Don’t force this tool into spots!  If the tool is too big for the line you are trying to bevel then skip it… We will have a chance to bevel that after we are done with all the long lines.  This will be the longest spot in the tooling process depending on the pattern.  This is where time is made because you have one tool to focus on and your running through line by line without regard for what you can’t bevel with this tool… just stay focused and bevel long lines.

Now all the long lines are beveled and you are ready to grab the medium beveler and proceed to working on any lines that were too small for the large beveler.  Same rule applies here, if it won’t fit skip it and wait till you have the small beveler in your hand.  This step goes much faster as you have already beveled the majority of the lines in the last step.  After completing this, I take my small beveler and clean up any small spots I couldn’t get before with the other two bevelers.

The next tool you will use is your bargrounders or whatever background tool you choose to use.  At this point all the lines should be beveled, making the background easy to determine.

When all the backgrounding is completed, now I use my thumbprint on all my flowers, leaves, and vinework.  This is where the detail work begins within the pattern.  The tools you use here is completely up to you.  The point is that now is where your pattern will start to take shape.  I also use my leaf liner where needed at this point.

After thumbprinting, or pear shading, you are ready for any fine detail stamping.  This step depends a lot on the style of the pattern that you are tooling.  Below is an example of the accent tools I selected for this pattern but you can incorporate any tools you like for this phase.  Take your time here and have fun… this is the decorative stage.

When you are satisfied with your stamping work within the pattern, now is the time to embelish with the final decorative cuts using your swivel knife.  Again, this is decorative so have fun and use this oppurtunity to work on your swivel knife mechanics.  Decorative knife cuts are the best training for overall proficiency in using the swivel knife.

Once the decorative cuts are completed the pattern is complete.  At this point, I will sometimes go back and undercut the pattern again just to relift the petals of leaves and flowers.  This step is optional and completely up to you and the final pattern.  If it looks good, leave it.

As I mentioned before, this is my process for tooling and yours may be different.  The main point to focus on is that in order to become more efficient in your stamping while maintaining quality you must have a system that you can work from no matter the pattern.  Tooling is like a dance and as long as you can go from one tool to the next smoothly, you will become faster and faster per piece.

 

Spacing holes quickly!

When it comes to punching holes for headstalls, tie straps, billets, or any other strap good you may be making, how do you layout your hole spacing?  Most people get the tap measure out and measure and mark each hole so they will be perfectly placed appropriately.  This is a fine way to do it if complete accuracy is mandatory.  If you are more focused on productive use of your time than perfection of hole spacing, try this method for both time and accuracy!

For the first hole use three fingers as your spacing from the tip to place your first hole.  On tie straps, I usually do a full hand width.

After making the first hole, I will use one finger width as my spacing for the rest of the holes.

Place your finger just past the first hole and use your finger as a guide for placement of the next hole.  Continue this for for each hole after.  On tie straps I use four fingers as my spacing.

This is a great time saver and unless you loose a finger in the middle of this,  your holes should be perfectly spaced.

2013 Big Loop Big Money Tour Finals

This is our fourth year to build the trophy saddles for the Big Loop Big Money Tour Finals put on by Philipp Ranch and we are so excited!

Held at the Brazos County Expo Center in Bryan, TX, the weekend includes team ropings from an Open division down to a #8, kids dummy roping competition and Philipp Ranch Production Horse sale! Starting Friday July 19- Sunday July 21st dont miss this great event!

 

For more information on this event and the production sale visit Philipp Ranch!

Putting a binder on.

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We are putting a cantle binder on first thing this morning. The binder has been skived where needed and glue applied, after which we will soak the binder in water so that it will be pliable to shape during installation. The binder will need the better part of the day to dry before hand sewing so we want to put them on in the morning first thing or last part of the day so we don’t waist time in the shop on it drying.

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Big Loop Ground Seats

Here is a quick run down of what projects are in process within the custom saddle department of our shop (this department consisting of Jim and I, ha ha): we have four customers’ orders from our list, each different and uniquely complex, two ranch saddles for the All Around Performance Horse crew (due in two weeks), and all fourteen of the Big Loop saddles.  This is all happening at the same time that the rest of the shop is busy on multiple belts, wallets, scabbards, holsters, saddle repairs and handling customers on a daily basis.  The oppurtunity for chaos is so great that it makes for an exciting work week this time of year.

My goal this week was to finish all the ground seats for the Big Loop saddles and get horns started.  Some of the saddles

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Working hard on the Big Loop saddles

had been started already, some ground seats were done and I wanted to get them all done completely so that Jim could focus on getting the All Around saddles to a point where I could get to tooling fronts or swells (my favorite… not).  Starting Monday with that goal in mind, I made progress and got all the ground seats completed by the end of the week.  Since this is usually the part that Jim takes care of, I was sure to check with him off and on to insure that I was putting the ground seats in the way he had been doing them.  It took me a couple times and a bit of Jim giving me hell, but in the end I got them all in.

Even though Jim and I both build saddles, we each do things a little different and consistency is what we want especially with this project.  For the last couple years, our partnership on saddle making has been him building and me tooling/designing all the artwork.  He is much faster than me at building and I am much faster than him at tooling, so this arrangement works well.  Since these are all rough out, and there is fourteen of them, I have custom saddle seatsto help him with a lot of the building and keeping up with changes he has made all year is something I have to be mindful of.  Even though my name is on the sign and stamp, Jim has the lead on this project… And I think he takes a little pleasure in bossing me around.

As the week went along uneventful and productively, it didn’t start off that great.  By Monday afternoon we were met with 85 degree temperatures in the shop.  Our air conditioner was froze up and not cooling at all.  Thinking back on the last few weeks, we realized that the filters hadn’t been changed and they really needed it.  In a shop like ours the dust can get pretty bad due to the sanding from the finisher so we have to change filters every two weeks or so.  It wasn’t till Tuesday afternoon late when our AC repair guys got us back up and running… till then we just tried not to drip sweat on the leather.

As we set now: ground seats are done, all the horns are cut out and skived, no major mistakes as of yet, a few shop pranks (involving an air horn) were conducted and the new guys haven’t quit yet.  It’s still early with lots left to do…

 

What we like to call, “The Big Loop Project”

So here we are again, our third year making the saddles for the Big Loop Big Money Tour put on by the Phillip Ranch.  This is by far the biggest project that my team and I orchestrate during the year… other than getting ready for the USTRC Finals in Oklahoma City.   The product list isn’t all that complicated, 14 solid rough out saddles with 14.5″ seats.  That doesn’t sound too difficult… because you don’t work in our shop.

My team of craftsmen (and craftswoman… sorry jodi) is by far the best group of talent in any shop… the problem is there aren’t very many of us.  Not to mention our lack of space that is needed to perform such a job… cramped quarters.  All of this combined with only having one sewing machine, only three draw down stands, two head knifes, no clicker, no band knife, and only two people who actually can build a saddle from start to finish.  Every year we build these saddles within a short time frame.

The thing to remember here is that our shop is a true custom shop that produces on average 4-5 saddles a month, each completely different in design and artwork.  We work in a manner that allows us to focus on the specifics that the customer requested and do the best possible job that we can.  Then what makes us want to take on such an endeavor and how do we shift gears to get the product completed at the same quality level and deliver on time?

WE HAVE NO IDEA… BUT WE DO IT!  HA HA!

When we first took the job on, we knew that it would be challenging to say the least.  What we didn’t realize is that in complicating things a bit and pushing ourselves beyond our comfort zone, we gain very valuable skills and techniques that allow us to become more efficient throughout the rest of the year while increasing the quality.

The first year was very stressful, constant worry and running close to the deadline… but quality was maintained.  The second year we finished with time to spare and quality increased a little.  This year we started earlier, working the saddles in with our customers orders, and feel more confident than last year.  That is not to say that we are not conscious of the task before us or too comfortable and wasting time.  We still have a lot to learn about the art of project planning and execution, but we do have a couple years behind us now and feel like every year has benefited us not only on this project but on all our projects year round.

So as we have already begun the “Big Loops” this year, I thought it would be fun to give an inside look at how we handle them and the chaos that could possibly insue within our little shop in Bryan, TX.  I will do my best to not only post about the triumphs, but also post on the screw ups and mishaps (hopefully we don’t have too many of those).  I have no idea how many post there will be or if it will be worth reading at all, but I will do my best.  I’m not going to lead you on, there usually isn’t ever a ton of shop drama, fist fights, crying, or firing of employees… but this is a new year so you never know!

We want to thank the Phillip Ranch for giving us this opportunity and all the ropers that spend their hard earned money and time traveling every month trying to win one of our saddles.  We will make sure that this year’s saddles are everything that has come to be expected from the Big Loop Big Money Tour Finals!

Pick Guard

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My brother, Ben Schane, brought his Martin guitar in the shop on a Saturday and after a song and a beer or two we did what anyone would do. We tore the pick guard off and made one out of thin Herman Oak leather. It was a lot of fun and turned out kinda cool.

Third year at the George Strait Team Roping

Well it’s upon us again. Seems like we just finished the Christmas season, and here we are set up at the George Strait Team roping Classic in San Antonio, TX.

This is our third year attending this event and we are looking forward to seeing our friends and making new ones. Like every year in the past, we try to start early and have two or three custom saddles made for this show. Again this year we were only able to bring one. With our growing order list and the demand our saddles have at home, we were only able to escape Brazos county with one.

This is the first time in our three years here that the weather has been bad. It’s currently raining and cold, so the ropers will have to contend with cold fingers if they want a chance at the money, truck and trailer.

Good luck to all the contestants! And to all the spectators, set back and enjoy some of the best team roping action on the planet!

Merry Christmas!

Driving to work this saturday morning, thinking to myself about the list of “have toos” and “if i cans” for the day, it struck me with a bit of excitement and fear. Fear, because i only have two weeks left to finish the gifts that have been ordered, and excitement because we are completing our seventh year in business. Unbelievable!

Seven years ago i was a 24 year old rookie saddle maker putting Vet school on hold to pursue an oppurtunity. My entire life up until this point had been focused on vet school and all of a sudden I had made the decision to give this oppurtunity a whirl. Thinking about it now, I should have been a bit more worried. But as with most of the things that i do, i made the decision and figured all the details would work themselves out.

I have absolutely no regrets in my decision to start DGSaddlery and have enjoyed every minute… Even the scary ones! As a group, we have been truely blessed and so grateful for the friendships that we have made. As we enter the christmas season again here in 2011 and prepare to begin our 8th year in business, we would like to thank all those customers who have supported us and who enjoy our work. Getting better every year is our main focus and we hope that this coming year will be no different. The thing that makes our products stand out is our customers’ imaginations and thanks to them, and our talented artists and craftsmen, we have had the oppurtunity to create some great products.

We hope that everyone has a wonderful christmas and we look forward to 2012 and putting your dreams in leather!