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DIY Kestrel Clone

These are awesome. Thanks for posting. I have neglected to check this forum for a bit due to family stuff.
I cant wait to get this done.
 
Quick question. What poundage of 1" webbing is suitable for the linemans loops?

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ckossuth said:
3000 lbs or greater. That’s what most quality 1” webbing is rated at.


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I've looked on Rockywoods site and others and all I find is 800 to 1000#. If anyone has a link to some it would be much appreciated!

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Just curious but are the legs straps mostly for comfort while in the saddle? I know they hold you in initially. To me it doesnt look like the leg straps are sewn with much material. I guess my main question is if the leg straps fail during a fall will you still be held in the harness by the belt?
 
Jwa13 said:
Just curious but are the legs straps mostly for comfort while in the saddle? I know they hold you in initially. To me it doesnt look like the leg straps are sewn with much material. I guess my main question is if the leg straps fail during a fall will you still be held in the harness by the belt?
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In my experience, the purpose they serve is to keep the saddle under your butt so it doesnt ride up your back. I cant imagine managing to fall out of one even if the leg straps failed.

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Ok so can someone please explain again how the panels are sewn together in order to get the cupping shape. I finished this up today and tested it but I was getting more pressure than I would have liked under my butt for lack of better words.
 

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Jwa13 said:
Ok so can someone please explain again how the panels are sewn together in order to get the cupping shape. I finished this up today and tested it but I was getting more pressure than I would have liked under my butt for lack of better words.
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The easiest way to build in cupping is to use multiple panels that are wider in the middle of the saddle and get smaller towards the bridge loops. Similar to the shape of a panel on a football but not as drastic a taper. It looks like your saddle was built with one panel. I hear rumor that you can build a single panel saddle with cup built in but have no clue how it’s done.
 
I haven’t read every thread in this thread but here’s a pic of the panels from @ckossuth original clone. When shaped this way it can’t help but be cupped after sewing it together.
837F956C-1254-40AF-B227-EF59FFB1D98E.jpeg
Also it’s hard to tell much detail on my phone looking at your pic. I don’t know if it’s really large thread or just because it’s black but it looks like you need to adjust the tension on your thread. It could just be the black thread but it just stands out like I’m seeing more thread than I should. It may be perfect and just looks that way.
 
I did lots of zig zag stitching basically it's way overbuilt. Also the order I assembled it caused a lot of overlapping stitching but the stitches themselves are tensioned correctly. I guess I consider it to be more of a prototype but I have no doubts about it being secure.
 
Yep. Sew the radiused edges of panels together to get a cupped shape.

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I starting working on one of these this weekend and cannot make heads or tails of the horizontal seam in the seat portion even after looking at the drawings. I ended up sewing a simple seam which seems (no pun intended) plenty strong especially with two panels sewn together and the majority of the weight carried by the seatbelt webbing. I'll ground test obviously, but just curious if there are strength advantages to the seam I can't seem (that one was intended) to figure out? Thanks all!
 
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I also struggled with this, then the light bulb moment so I hope this helps, first put the panels together on top of each other good side in and stitch along this line.
69347376_389980051706621_2814199122234441728_n.jpg
then unfold the right way up and fold the seam downwards like this
69136415_406244256683720_712234053033525248_n.jpg
here you see the second stitch from underneath, but here it is starting from good side out
68703882_371996633480374_3796690388891205632_n.jpg
all you are doing is one stitch then folding the hem down and stitching again close to your first stitch, hope this helps ps the hem lays flat and isn't felt and is a good strong seam,regards wayne
 
wayne r said:
I also struggled with this, then the light bulb moment so I hope this helps, first put the panels together on top of each other good side in and stitch along this line.
View attachment 17078
then unfold the right way up and fold the seam downwards like this
View attachment 17079
here you see the second stitch from underneath, but here it is starting from good side out
View attachment 17080
all you are doing is one stitch then folding the hem down and stitching again close to your first stitch, hope this helps ps the hem lays flat and isn't felt and is a good strong seam,regards wayne
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Thanks Wayne! Makes perfect sense now. I appreciate your time to answer that question!
-Justin
 
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