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WESTERN SHAPED EAR HEADSTALLS
TABLE OF CONTENTS

The designs and styles of shaped ear headstalls is only limited by one's imagination.  Therefore, four common examples are listed.   
                   
The size or width of a headstall is determined by the head strap and can be anywhere between 1/2" to 1" with 5/8" being the most common.  Therefore, the examples below the width or size is based on 5/8", you will need to adjust the data for other widths.   
NOTE:  
If the item is shaped, the times are based upon the item being hand cut from a pattern;  if a clicker die is used the times will be reduced.  
Also if the item is shaped, the dimensions used in the materials list are based on the outside measurements of the item.
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 5/8" SINGLE PLY HARNESS LEATHER SHAPED EAR HEADSTALL
WITH SEWN DOUBLE HEEL BUCKLES AND SHAPED CHEEKS
AND CHICAGO SCREWS AT THE BIT END



MATERIALS LIST AND COSTS  – Based on average costs and times for a saddle maker with 3/5 years of experience
AMOUNT
DESCRIPTION
COST
TOTAL
1.06
SQ FT MEDIUM HARNESS LEATHER
11.17
11.84
2
5/8" SS OR SB HEEL BUCKLES
0.79
1.58
2
CHICAGO SCREWS          
0.16
0.32
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
2.37
     MATERIALS COST
16.11
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
0.85
MATERIALS TOTAL COST
16.96

.58
HOURS OF LABOR NEEDED TO MANUFACTURE ITEM          

 { The shop rate is the total of your hourly wage and an hourly rate to cover your overhead costs }
SHOP RATE TOTAL
MATERIALS
&
 SHOP RATE
TOTAL
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF   $ 40.00 PER HOUR
23.20
40.16
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
26.10
43.06
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
29.00
45.96
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
31.90
48.86
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
34.80
51.76
TIMES  – Based on average times for a saddle maker with 3/5 years of experience
PROCESS
TIMES    (minutes)
CUT
4.75
LEVEL (SPLIT) Optional
1.00
MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, SKIVE, AND FINISH ENDS
3.00
PUNCH HOLES IN HEAD STRAP FOR CHEEK BUCKLE
1.00
SEW ON CHEEK BUCKLES AND PUNCH HOLES FOR CHICAGO SCREWS
7.75
EDGE
6.00
TOP COAT
1.00
DYE EDGES
5.00
ASSEMBLE
5.00
     TOTAL MINUTES
34.50
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
0.58

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
SHAPED EAR BODY CUT WITH CLICKER DIE  APPROX  -  3" X 27"
3
27
81.00
2
CHEEK BODIES  – CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 15 ½"
1.25
15.5
38.75
2
5/8" KEEPER STRAP - 1/2" X 2 1/4"
0.5
2.25
2.25
     TOTAL SQ INCHES
122.00
          25% WASTE SQ INCHES
30.50
               TOTAL SQ FT
1.06


 5/8" SINGLE PLY HARNESS LEATHER SHAPED EAR HEADSTALL
WITH SEWN DOUBLE HEEL BUCKLES AND SHAPED CHEEKS
WITH CHICAGO SCREWS AT THE BIT END AND THROAT LATCH



MATERIALS LIST AND COSTS  – Based on average costs and times for a saddle maker with 3/5 years of experience
AMOUNT
DESCRIPTION
COST
TOTAL
1.24
SQ FT MEDIUM HARNESS LEATHER
11.17
13.85
2
5/8" SS OR SB HEEL BUCKLES
0.79
1.58
1
1/2" SS OR SB HEEL BUCKLE
0.76
0.76
2
CHICAGO SCREWS          
0.16
0.32
2
5/8" DEES
0.26
0.52
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
2.77
     MATERIALS COST
19.80
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
1.04
MATERIALS TOTAL COST
20.84

.71
HOURS OF LABOR NEEDED TO MANUFACTURE ITEM          

 { The shop rate is the total of your hourly wage and an hourly rate to cover your overhead costs }
SHOP RATE TOTAL
MATERIALS
&
 SHOP RATE
TOTAL
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF   $ 40.00 PER HOUR
28.40
49.24
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
31.95
52.79
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
35.50
56.34
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
39.05
59.89
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
42.60
63.44
TIMES  – Based on average times for a saddle maker with 3/5 years of experience
PROCESS
TIMES    (minutes)
CUT
2.50
LEVEL (SPLIT) Optional
1.00
MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, SKIVE, AND FINISH ENDS
3.00
MAKE-UP THROAT LATCH BUCKLE AND BILLET STRAPS AND STITCH THROAT LATCH CROWN STRAP TO SHAPED EAR BODY     
9.50
SEW ON CHEEK BUCKLES AND PUNCH HOLES FOR CHICAGO SCREWS
7.75
EDGE
6.00
TOP COAT
1.00
DYE EDGES
5.00
PUNCH HOLES IN HEAD STRAP FOR CHEEK BUCKLE
1.00
ASSEMBLE
6.00
     TOTAL MINUTES
42.75
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
0.71

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
SHAPED EAR BODY CUT WITH CLICKER DIE  APPROX 3" X 27"
3
27
81.00
2
SHAPED CHEEK BODIES CUT WITH CLICKER DIE APPROX 1 1/8" X 16"
1.125
16
36.00
1
THROAT LATCH CROWN STRAP  5/8" X 15"
.625
15
9.38
1
THROAT LATCH BILLET STRAP  1/2" X 12"
.5
12
0.25
1
THROAT LATCH BUCKLE STRAP  1/2" X 27
.5
27
13.50
1
1/2" KEEPER STRAP  1/2" X 2"
.5
2
1.00
2
5/8" KEEPER STRAPS  1/2" X 2 1/4"
.5
2.25
2.25
     TOTAL SQ INCHES
143.38
          25% WASTE SQ INCHES
35.84
               TOTAL SQ FT
1.24


 5/8" DOUBLED AND STITCHED SHAPED EAR HEADSTALL
WITH SEWN DOUBLE HEEL BUCKLES AND SHAPED CHEEKS
WITH CHICAGO SCREWS AT THE BIT END AND THROAT LATCH



MATERIALS LIST AND COSTS  – Based on average costs and times for a saddle maker with 3/5 years of experience
AMOUNT
DESCRIPTION
COST
TOTAL
2.26
SQ FT BRIDLE LEATHER OF YOUR CHOICE
10.60
23.96
2
5/8" SS OR SB HEEL BUCKLES
0.79
1.58
1
1/2" SS OR SB HEEL BUCKLES                    
0.76
0.76
2
CHICAGO SCREWS          
0.16
0.32
2
5/8" DEES
0.26
0.52
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
4.79
     MATERIALS COST
31.93
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
1.68
MATERIALS TOTAL COST
33.61

1.17
HOURS OF LABOR NEEDED TO MANUFACTURE ITEM          

 { The shop rate is the total of your hourly wage and an hourly rate to cover your overhead costs }
SHOP RATE TOTAL
MATERIALS
&
 SHOP RATE
TOTAL
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF   $ 40.00 PER HOUR
46.80
80.41
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
52.65
86.26
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
58.50
92.11
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
64.35
97.96
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
70.20
103.81
TIMES  – Based on average times for a saddle maker with 3/5 years of experience
PROCESS
TIMES    (minutes)
CUT AND LEVEL (SPLIT)
10.50
MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, AND FINISH ENDS
3.00
MAKE-UP HEAD STRAP ( GLUE, STITCH, AND TRIM  AS NEEDED )
9.00
MAKE-UP THROAT LATCH BUCKLE AND BILLET STRAPS AND STITCH THROAT LATCH CROWN STRAP TO SHAPED EAR BODY     
9.50
MAKE UP CHEEKS ( GLUE, STITCH, AND TRIM  AS NEEDED )
15.00
EDGE
6.00
DYE EDGES
5.00
TOP COAT
1.00
ASSEMBLE
11.00
     TOTAL MINUTES
70.00
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
1.17

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
2
SHAPED EAR BODY CUT WITH CLICKER DIE  APPROX 3" X 27"
3
27
162.00
4
SHAPED CHEEK BODIES CUT WITH CLICKER DIE APPROX 1 1/8" X 16"
1.125
16
72.00
1
THROAT LATCH CROWN STRAP  5/8" X 15"
.625
15
9.38
1
THROAT LATCH BILLET STRAP  1/2" X 12"
.5
12
0.25
1
THROAT LATCH BUCKLE STRAP  1/2" X 27
.5
27
13.50
1
1/2" KEEPER STRAP  1/2" X 2"
.5
2
1.00
2
5/8" KEEPER STRAPS  1/2" X 2 1/4"
.5
2.25
2.25
     TOTAL SQ INCHES
260.38
          25% WASTE SQ INCHES
65.09
               TOTAL SQ FT
2.26


 5/8" LINED SHAPED EAR HEADSTALL WITH SEWN DOUBLE HEEL BUCKLES
AND SHAPED CHEEKS WITH LATIGO TIES AT THE BIT END AND THROAT LATCH


MATERIALS LIST AND COSTS  – Based on average costs and times for a saddle maker with 3/5 years of experience
AMOUNT
DESCRIPTION
COST
TOTAL
1.24
SQ FT BRIDLE LEATHER OF YOUR CHOICE
10.60
13.14
1.04
4/5 OZ LINING LEATHER OF YOUR CHOICE
10.20
10.61
2
5/8" SS OR SB HEEL BUCKLES                    
0.79
1.58
1
1/2" SS OR SB HEEL BUCKLES                    
0.76
0.76
2
5/8" DEES
0.26
0.52
2
LATIGO TIES          
0.44
0.88
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
2.63
     MATERIALS COST
30.12
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
1.59
MATERIALS TOTAL COST
31.71

1.22
HOURS OF LABOR NEEDED TO MANUFACTURE ITEM          

 { The shop rate is the total of your hourly wage and an hourly rate to cover your overhead costs }
SHOP RATE TOTAL
MATERIALS
&
 SHOP RATE
TOTAL
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF   $ 40.00 PER HOUR
48.80
80.51
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
54.90
86.61
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
61.00
92.71
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
67.10
98.81
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
73.20
104.91

TIMES  – Based on average times for a saddle maker with 3/5 years of experience
PROCESS
TIMES    (minutes)
CUT AND LEVEL (SPLIT)
13.50
MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, AND FINISH ENDS
3.00
MAKE-UP HEAD STRAP ( GLUE, STITCH, AND TRIM  AS NEEDED )
9.00
MAKE-UP THROAT LATCH BUCKLE AND BILLET STRAPS AND STITCH THROAT LATCH CROWN STRAP TO SHAPED EAR BODY     
9.50
MAKE UP CHEEKS ( GLUE, STITCH, AND TRIM  AS NEEDED )
15.00
EDGE
6.00
DYE EDGES
5.00
TOP COAT
1.00
ASSEMBLE
11.00
     TOTAL MINUTES
73.00
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
1.22

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
SHAPED EAR BODY CUT WITH CLICKER DIE  APPROX 3" X 27"
3
27
81.00
2
SHAPED CHEEK BODIES CUT WITH CLICKER DIE APPROX 1 1/8" X 16"
1.125
16
36.00
1
THROAT LATCH CROWN STRAP  5/8" X 15"
.625
15
9.38
1
THROAT LATCH BILLET STRAP  1/2" X 12"
.5
12
0.25
1
THROAT LATCH BUCKLE STRAP  1/2" X 27
.5
27
13.50
1
1/2" KEEPER STRAP - 1/2" X 2"
0.5
2
1.00
2
5/8" KEEPER STRAP - 1/2" X 2 1/4"
0.5
2.25
2.25
     TOTAL SQ INCHES
143.38
          25% WASTE SQ INCHES
35.84
               TOTAL SQ FT
1.24
MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
SHAPED EAR BODY CUT WITH CLICKER DIE  APPROX 3" X 27"
3
27
81.00
2
CHEEK BODIES  – CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 15 ½"
1.25
15.5
38.75
     TOTAL SQ INCHES
119.75
          25% WASTE SQ INCHES
29.94
               TOTAL SQ FT
1.04


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