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First attempt at a saddle (Transformer - Clone)

jhunter13

jhunter13

Well-Known Member
SH Member
Joined
Jun 6, 2020
Messages
654
This was my first attempt at bulding a saddle. Id like to thank everyone who contributes to the site and thank @JCLINE84 for his help getting me going.

I will add some in progress pics tomorrow along with the material list.
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I’m very impressed with this build. I helped a little with some initial measurements but you nailed it on the execution. It’s a very complicated saddle to build even after you know all of the measurements and layout. And you did a heck of a job on it.
 
JCLINE84 said:
I’m very impressed with this build. I helped a little with some initial measurements but you nailed it on the execution. It’s a very complicated saddle to build even after you know all of the measurements and layout. And you did a heck of a job on it.
Click to expand...
Thanks Jaime. Definitely had to think 3 or 4 steps ahead at times and even hand wheel some areas for better control.
 
JCLINE84 said:
I’m very impressed with this build. I helped a little with some initial measurements but you nailed it on the execution. It’s a very complicated saddle to build even after you know all of the measurements and layout. And you did a heck of a job on it.
Click to expand...

And I am super impressed that you are helping someone DIY a saddle you make and sell. Says a ton about you and your character!
 
Here is the list of materials I ordered. I ordered 4 or 5 times more than I needed due to shipping costs. Glad I did, as I am already planning the next saddle to build.

Webbing
Main suspension (1 3/4" Berry compliant webbing): https://www.countrybrookdesign.com/...low-stripes-heavy-nylon-webbing-closeout.html
Leg straps/Molle/Linemans Loops: https://www.amazon.com/Country-Brook-Design-Durable-Webbing/dp/B003ILSW3A?th=1
Panel adjustment webbing: https://www.amazon.com/Strapworks-M...+17338+strap+for+slings&qid=1619357945&sr=8-2

Panels are two layers of 500d cordura with 1 inch grosgrain trimmed
www.ebay.com

500D Coated Cordura Camouflage 60"W Fabric Strata Camo True Timber DWR Hunting | eBay

Find many great new & used options and get the best deals for 500D Coated Cordura Camouflage 60"W Fabric Strata Camo True Timber DWR Hunting at the best online prices at eBay! Free shipping for many products!
www.ebay.com
www.ebay.com

Coyote Brown 500D Cordura 60"W Urethane Coated Military Nylon DWR Fabric By Yard | eBay

Find many great new & used options and get the best deals for Coyote Brown 500D Cordura 60"W Urethane Coated Military Nylon DWR Fabric By Yard at the best online prices at eBay! Free shipping for many products!
www.ebay.com

1 inch (25mm) CORDURA® TRUELOCK™, Mil-Spec Grosgrain Ribbon

1" Mil-prf-5038 Grosgrain Ribbon, textured
www.rockywoods.com www.rockywoods.com

Hardware
Fusion Climb D-Ring: https://doublesteps.com/product/aluminum-d-ring/
Tri-glide for belt: https://austrialpin.net/product/cobra-original-adjustable/
Belt buckle: https://austrialpin.net/product/belt-buckles/
Leg strap attachment/adjustment hardware: https://austrialpin.net/product/belt-buckles/
Leg strap buckles: https://doublesteps.com/product/adf-raptor-1-buckle/
Panel Adjustment: https://www.rockywoods.com/ITW-Nexus-1-Ladderlock-Buckles-Coyote-498

Thread:
Tera 40 to attach panels/grosgrain: https://www.rockywoods.com/Gutermann-TERA-40-Polyester-Thread
V-92 for all webbing: https://www.sailrite.com/Thread-V-92-Polyester-Beige-UV-4oz-1-050-Yds

Sewing Machines:
I am using two Singer 15-91 sewing machines. One is a 1934 and the other is a 1954. I set them up for the different threads so I wouldn't have to adjust tensions throughout the project. These 15-91's impressed the heck out me and had no problem sewing any portion of this saddle. I did run into one spot where the needle was deflecting through 6 layers of material that I had to hand wheel to keep the needle aligned and from hitting the plate
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bowhuntr09 said:
And I am super impressed that you are helping someone DIY a saddle you make and sell. Says a ton about you and your character!
Click to expand...

When I first reached out to him for a question I started it with "Not asking to give away any secrets" as I thought no way someone would actually help me make a clone of their saddle. He gave me just enough help on some measurement so I could figure things out from there. I have read it time and time again on here, and now I will say it again - Jaime is a stand up guy.
 
jhunter13 said:
When I first reached out to him for a question I started it with "Not asking to give away any secrets" as I thought no way someone would actually help me make a clone of their saddle. He gave me just enough help on some measurement so I could figure things out from there. I have read it time and time again on here, and now I will say it again - Jaime is a stand up guy.
Click to expand...

Makes me want to buy a saddle from him just to support him and god knows I already own too many. :tearsofjoy:
 
Calculations for Load Bearing
I used the following site (which is a must read for anyone sewing webbing) to calculate my stich length for sewing the main suspension together.
www.sailrite.com

How to Sew Webbing Loops

Learn what the strongest stitch patterns are for sewing webbing loops and how to sew webbing for load bearing applications using a handy formula.
www.sailrite.com www.sailrite.com

The main suspension has a 6000 lb tensile strength. Below are my calculations:

The equation: SPI x Thread Tensile Strength x 1.5 = seam strength per inch. (1.5 is the average loop strength according to sailrite).

I used 8 stiches per inch (SPI) and V-92 tensile strength is 15lbs.

So 8 SPI x 15 lbs x 1.5 = 180 lbs/inch

I decided to match my seam strength to the webbing strength and chose a Minimum Breaking Strength (MBI) if 6000 lbs.

To determine how many inches of sewing I need to reach this MBS I divided my MBS by 180 lbs/inch.

So 6000 / 180 = 33.3 inches. This is how many inches of seam I needed to sew to obtain a MBS of 6000 lbs. It probably ended up being closer to 40 by the time I was done.

I went with a "W" sewing pattern and I recommend using a ruler and some chalk to draw the pattern before you start sewing to ensure you hit the calculated length of stiches to meet your MBS. (It may be hard to see the stitch pattern in the picture as the thread matches the webbing)W Stiches.jpg
 
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Here are a few of pictures during the build.

Front and back of completed panels Pic 1.jpg
Pic 2.jpg

Panels sewn into suspension webbing Pic 3.jpg

Close up of some stitching

Pic 5.jpg

Test sit from the basement rafters

Test Sit.PNG

Linemans loops before sewing onto saddle
LB 1.jpg
LB2.jpg
 
How did the singers handle that fold over for the lineman loops? That’s one of the hardest/most dense parts of the saddle in my experience. I’ve had my 1508 stutter with it before.
 
JCLINE84 said:
How did the singers handle that fold over for the lineman loops? That’s one of the hardest/most dense parts of the saddle in my experience. I’ve had my 1508 stutter with it before.
Click to expand...
The singers dont like to run slow. So I had to give the wheel a hand to get it started, but no problems after that. I had a harder time figuring out how to fold and hold it all together. Found out binder clips are worth their weight in gold!
 
jhunter13 said:
The singers dont like to run slow. So I had to give the wheel a hand to get it started, but no problems after that. I had a harder time figuring out how to fold and hold it all together. Found out binder clips are worth their weight in gold!
Click to expand...
I actually just do the whole thing by hand without clips but I fold the cordura around the webbing then sew down the center to hold it. Then fold and sew the wrapped portion to create the stiff lineman loop.
 
JCLINE84 said:
I actually just do the whole thing by hand without clips but I fold the cordura around the webbing then sew down the center to hold it. Then fold and sew the wrapped portion to create the stiff lineman loop.
Click to expand...
If you look closely at my loops youll see the stitching to close them is off centered. I sewed a 2 1/4" peice of cordura to the webbing, then folded the cordura over, then the entire thing in half and clipped. I sewed them off center to ensure I caught the cordura in the fold. Your way sounds way easier.
 
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