MATERIALS
500d Cordura in Multicam (bought 2 yards on eBay) - $23 -
LINK HERE
1 3/4" MIL SPEC Dive Belt Webbing (bought 10 yards on eBay) - $20 -
LINK HERE
Nylon Upholstery thread for all stitching (bought on amazon) - $4 -
LINK HERE
1" Coyote webbing for molle loops (you'll need about 8 foot) - $15 -
LINK HERE
1 3/4" Cobra buckle (fixed male, adjustable female) - $14 -
LINK HERE
1/4" Amsteel Blue (25 ft) - $33 -
LINK HERE
I stitched everything with my Singer Heavy Duty sewing machine. -
LINK HERE
Everything above cost $109 (excluding the sewing machine). The quantities will easily make 3 or 4 custom saddles, just get more buckles. I already had the Amsteel, 1" webbing, and thread. I only spent about $60 total.
PROCESS
The Cordura was cut at 22" wide and 30" long. I folded it in half to have a finished size of 11"x30". I chose this length because it was about 4" longer and wider than my SitDrag. if you are a bigger guy, I'd recommend going a little longer than 30" to eliminate any hip pinch. You can measure around your butt to right in front of your hips. That's how wide I would recommend the seat being.
The first step is to make your bridge. I made 2 locked brummels following this guide. You need to bury about 8" for a strong hold.
It's very easy if you have fids. I bought the
Samson Rope Splicing Kit years ago. If that's too much, go with a
cheaper version here. Or you can buy knitting needles at Walmart and make your own following this guide.
The first step was to sew the edges of the cordura following this guide.
After the edges were stitched, I sewed in the webbing that formed the structure of the saddle. I stitched around the entire length of the webbing on top and bottom. Then I added in reinforcing stitches near the ends of the seat and at the bottom where the ends terminated. I probably went a little overboard with the stitching. I have several thousand stitches in the webbing.
***MAKE SURE TO CAPTURE YOUR BRIDGE LOOPS BEFORE YOU SEW IN THE WEBBING***
Next, I added in the belt and buckle. I stitched all the way around the belt and added reinforced stitches near the edges. I sewed the fixed male buckle end with a box stitch. I left plenty of tag for my adjustable female buckle.
After the belt was complete, I folded the loops in thirds and ran a line of stitching down the entire length. This makes clipping carabiners on and off very easy.
After that, you're basically done. All that's left to do is add the molle webbing for attaching gear. That's as easy as sewing 2 rows of 1" slots all the way around the seat using your 1" webbing. You should leave a small 1" gap in between the two rows of webbing. This is how molle webbing is supposed to work in case you are unfamiliar.
Once your molle is complete, the saddle is ready. You can then customize further.
Please keep in mind I am not a seamstress, or professional gear maker. I am only showing this to demonstrate what can be done. I DO NOT recommend you follow this without consulting a professional. I DO NOT recommend you make your own saddle.
