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WESTERN SLIDING EAR HEADSTALLS
TABLE OF CONTENTS
The designs and styles of sliding ear headstalls is only limited by one's imagination.  Therefore, a few generic 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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HARNESS LEATHER
BRIDLE LEATHER




 5/8" SINGLE PLY HARNESS LEATHER SLIDING EAR HEADSTALL WITH SEWN DOUBLE HEEL BUCKLES AND SHAPED CHEEKS WITH LATIGO TIES 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
.80
SQ FT MEDIUM HARNESS LEATHER
11.17
8.94
2
5/8" SS OR SB HEEL BUCKLES
0.79
1.58
2
LATIGO TIES          
0.44
0.88
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
1.79
     MATERIALS COST
13.18
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
0.69
MATERIALS TOTAL COST
13.88

.61
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
24.40
38.28
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
27.45
41.33
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
30.50
44.38
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
33.55
47.43
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
36.60
50.48






















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
MAKE-UP SLIDING EAR
4.50
PUNCH HOLES IN HEAD STRAP FOR CHEEK BUCKLE
1.00
SEW ON CHEEK BUCKLES AND PUNCH HOLES FOR CHICAGO SCREWS
7.75
MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, SKIVE, AND FINISH ENDS
3.00
EDGE
6.00
TOP COAT
1.00
DYE EDGES
5.00
ASSEMBLE
5.00
     TOTAL MINUTES
36.75
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
0.61

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
CROWN STRAP  - 5/8" X 28"
.625
28
17.50
1
SLIDING EAR BODY -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 4 3/4" X 7
4.75
7
33.25
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
91.75
          25% WASTE SQ INCHES
22.94
               TOTAL SQ FT
0.80





 5/8" SINGLE PLY HARNESS LEATHER SLIDING EAR HEADSTALL WITH 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
1.00
SQ FT MEDIUM HARNESS LEATHER
11.17
11.17
2
5/8" SS OR SB HEEL BUCKLES
0.79
1.58
1
1/2" SS OR SB HEEL BUCKLE
0.76
0.76
8
CHICAGO SCREWS          
0.16
1.28
2
5/8" TUCK LOOPS OR LATIGO TIES
0.13
0.26
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
2.23
     MATERIALS COST
17.28
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
0.91
MATERIALS TOTAL COST
18.19

.68
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
27.20
45.39
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
30.60
48.79
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
34.00
52.19
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
37.40
55.59
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
40.80
58.99























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
MAKE-UP KEEPERS
3.75
MAKE-UP SLIDING EAR
4.50
MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, SKIVE, AND FINISH ENDS
3.00
EDGE
6.00
TOP COAT
1.00
DYE EDGES
5.00
PUNCH HOLES IN HEAD STRAP FOR CHEEK BUCKLE
1.00
PUNCH HOLES FOR CHICAGO SCREWS ON CHEEK STRAPS
4.25
PUNCH HOLES FOR CHICAGO SCREWS  THROAT LATCH  BUCKLE AND PUNCH HOLES FOR BUCKLE               
2.75
ASSEMBLE
6.00
     TOTAL MINUTES
40.75
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
0.68

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
CROWN STRAP  - 5/8" X 28"
.625
28
17.50
1
SLIDING EAR BODY -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 4 3/4" X 7
4.75
7
33.25
1
THROAT LATCH STRAP  - ½" X 44"
.5
44
22.00
2
CHEEK BODIES  – CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 15 ½"
1.25
15.5
38.75
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
114.75
          25% WASTE SQ INCHES
28.69
               TOTAL SQ FT
1.00





 HALF SLIDING EAR
5/8" SINGLE PLY HARNESS LEATHER HEADSTALL WITH DOUBLE HEEL BUCKLES ATTACHED WITH CHICAGO SCREWS AND SHAPED CHEEKS WITH 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
.66
SQ FT MEDIUM HARNESS LEATHER
11.17
7.37
2
5/8" SS OR SB HEEL BUCKLES
0.79
1.58
2
LATIGO TIES          
0.44
0.88
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
1.47
     MATERIALS COST
11.31
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
0.60
MATERIALS TOTAL COST
11.90

.63
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
25.20
37.10
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
28.35
40.25
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
31.50
43.40
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
34.65
46.55
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
37.80
49.70
TIMES  – Based on average times for a saddle maker with 3/5 years of experience
PROCESS
TIMES    (minutes)
CUT
4.50
LEVEL (SPLIT) Optional
1.00
MAKE-UP SLIDING EAR PORTION OF CROWN STRAP
3.50
PUNCH HOLES IN HEAD STRAP FOR CHEEK BUCKLE
1.00
SEW ON CHEEK BUCKLES AND PUNCH HOLES FOR CHICAGO SCREWS
7.75
MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, SKIVE, AND FINISH ENDS
3.00
EDGE
6.00
TOP COAT
1.00
DYE EDGES
5.00
ASSEMBLE
5.00
     TOTAL MINUTES
37.75
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
0.63

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
CROWN STRAP AND SLIDING EAR  -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 28"     
1.25
28
35.00
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
76.00
          25% WASTE SQ INCHES
19.00
               TOTAL SQ FT
0.66





 5/8" DOUBLED AND STITCHED BRIDLE LEATHER SLIDING EAR HEADSTALL
WITH DOUBLE HEEL BUCKLES
ATTACHED WITH CHICAGO SCREWS AND
SHAPED CHEEKS WITH 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
1.41
SQ FT BRIDLE LEATHER OF YOUR CHOICE
10.60
14.95
2
5/8" SS OR SB HEEL BUCKLES
0.79
1.58
8
CHICAGO SCREWS          
0.16
1.28
2
5/8" TUCK LOOPS OR LATIGO TIES
0.13
0.26
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
2.99
     MATERIALS COST
21.06
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
1.11
MATERIALS TOTAL COST
22.16

1.16
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
46.40
68.56
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
52.20
74.36
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
58.00
80.16
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
63.80
85.96
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
69.60
91.76
TIMES  – Based on average times for a saddle maker with 3/5 years of experience
PROCESS
TIMES    (minutes)
CUT AND LEVEL (SPLIT)
12.50
MAKE-UP HEAD STRAP ( GLUE, STITCH, AND TRIM  AS NEEDED )
9.00
MAKE-UP SLIDING EAR PIECE ( GLUE, STITCH, AND TRIM  AS NEEDED )
7.00
MAKE UP CHEEKS ( GLUE, STITCH, AND TRIM  AS NEEDED )
15.00
MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, AND FINISH ENDS
3.00
EDGE
6.00
DYE EDGES
5.00
TOP COAT
1.00
ASSEMBLE
11.00
     TOTAL MINUTES
69.50
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
1.16

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
2
CROWN STRAP  - 5/8" X 28"
.625
28
35.00
1
SLIDING EAR BODY -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 4 3/4" X 7
4.75
7
33.25
1
SLIDING EAR BODY LINER  -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 4 3/4" X 3"
4.75
3
14.25
4
CHEEK BODIES  – CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 15 ½"
1.25
15.5
77.50
2
5/8" KEEPER STRAP - 1/2" X 2 1/4"
0.5
2.25
2.25
     TOTAL SQ INCHES
162.25
          25% WASTE SQ INCHES
40.56
               TOTAL SQ FT
1.41





 5/8" LINED BRIDLE LEATHER SLIDING EAR HEADSTALL
WITH DOUBLE HEEL BUCKLES ATTACHED WITH CHICAGO SCREWS
AND SHAPED CHEEKS WITH 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
.81
SQ FT BRIDLE LEATHER OF YOUR CHOICE
10.60
8.59
.61
4/5 OZ LINING LEATHER OF YOUR CHOICE
10.20
6.22
2
5/8" SS OR SB HEEL BUCKLES                    
0.79
1.58
8
CHICAGO SCREWS          
0.16
1.28
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
1.72
     MATERIALS COST
19.39
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
1.02
MATERIALS TOTAL COST
20.41

1.28
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
51.20
71.61
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
57.60
78.01
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
64.00
84.41
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
70.40
90.81
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
76.80
97.21
TIMES  – Based on average times for a saddle maker with 3/5 years of experience
PROCESS
TIMES    (minutes)
CUT AND LEVEL (SPLIT)
12.50
MAKE-UP HEAD STRAP ( GLUE, STITCH, AND TRIM  AS NEEDED )
9.00
MAKE-UP BROW ( GLUE, STITCH, AND TRIM  AS NEEDED )
8.00
MAKE UP CHEEKS ( GLUE, STITCH, AND TRIM  AS NEEDED )
15.00
MAKE-UP THROAT LATCH ( GLUE, STITCH, AND TRIM  AS NEEDED )
6.00
MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, AND FINISH ENDS
3.00
EDGE
6.00
DYE EDGES
5.00
TOP COAT
1.00
ASSEMBLE
11.00
     TOTAL MINUTES
76.50
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
1.28

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
CROWN STRAP  - 5/8" X 28"
.625
28
17.50
1
SLIDING EAR BODY -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 4 3/4" X 7
4.75
7
33.25
2
CHEEK BODIES  – CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 15 ½"
1.25
15.5
38.75
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
92.75
          25% WASTE SQ INCHES
23.19
               TOTAL SQ FT
0.81
MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
CROWN STRAP  - 5/8" X 28"
.625
28
17.50
1
SLIDING EAR BODY LINER  -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 4 3/4" X 3"
4.75
3
14.25
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
70.50
          25% WASTE SQ INCHES
17.63
               TOTAL SQ FT
0.61



 5/8" DOUBLED AND STITCHED  BRIDLE LEATHER DOUBLE SLIDING EAR HEADSTALL
WITH DOUBLE HEEL BUCKLES ATTACHED WITH CHICAGO SCREWS
AND SHAPED CHEEKS WITH 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
1.82
SQ FT BRIDLE LEATHER OF YOUR CHOICE
10.60
19.29
2
5/8" SS OR SB HEEL BUCKLES
0.79
1.58
8
CHICAGO SCREWS          
0.16
1.28
2
5/8" TUCK LOOPS OR LATIGO TIES
0.13
0.26
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
3.86
     MATERIALS COST
26.27
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
1.38
MATERIALS TOTAL COST
27.65

1.26
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
50.40
78.05
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
56.70
84.35
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
63.00
90.65
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
69.30
96.95
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
75.60
103.25


TIMES  – Based on average times for a saddle maker with 3/5 years of experience
PROCESS
TIMES    (minutes)
CUT AND LEVEL (SPLIT)
12.50
MAKE-UP HEAD STRAP ( GLUE, STITCH, AND TRIM  AS NEEDED )
9.00
MAKE-UP SLIDING EAR PIECE ( GLUE, STITCH, AND TRIM  AS NEEDED )
13.00
MAKE UP CHEEKS ( GLUE, STITCH, AND TRIM  AS NEEDED )
15.00
MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, AND FINISH ENDS
3.00
EDGE
6.00
DYE EDGES
5.00
TOP COAT
1.00
ASSEMBLE
11.00
     TOTAL MINUTES
75.50
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
1.26

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
2
CROWN STRAP  - 5/8" X 28"
.625
28
35.00
2
SLIDING EAR BODY -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 4 3/4" X 7
4.75
7
66.50
2
SLIDING EAR BODY LINER  -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 4 3/4" X 3"
4.75
3
28.50
4
CHEEK BODIES  – CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 15 ½"
1.25
15.5
77.50
2
5/8" KEEPER STRAP - 1/2" X 2 1/4"
0.5
2.25
2.25
     TOTAL SQ INCHES
209.75
          25% WASTE SQ INCHES
52.44
               TOTAL SQ FT
1.82


Copyright 2005 - 2016 American Saddle Makers Association, Inc.