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WESTERN SPLIT EAR HEADSTALLS
TABLE OF CONTENTS

As with the other headstalls the designs and styles of split ear headstalls is only limited by one's imagination.  Therefore, four 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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 3/4" SINGLE PLY HARNESS LEATHER SPLIT EAR HEADSTALL
WITH SEWN DOUBLE BAR BUCKLE AND 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
.45
SQ FT MEDIUM HARNESS LEATHER
11.17
3.91
1
3/4" SS OR SB CENTER BAR BUCKLE
1.02
1.02
2
LATIGO TIES          
0.44
0.88
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
0.78
     MATERIALS COST
6.59
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
0.35
MATERIALS TOTAL COST
6.94

.43
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
17.20
24.14
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
19.35
26.29
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
21.50
28.44
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
23.65
30.59
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
23.65
30.59
TIMES  – Based on average times for a saddle maker with 3/5 years of experience
PROCESS
TIMES    (minutes)
CUT
2.00
LEVEL (SPLIT) Optional
1.00
MARK HOLES FOR BUCKLE, BUCKLE SLOT, LATIGO TIES, SKIVE, AND FINISH ENDS
1.75
MAKE-UP CROWN STRAP
4.50
PUNCH HOLES IN HEAD STRAP FOR CHEEK BUCKLE
1.00
SEW ON CHEEK BUCKLE AND PUNCH HOLES FOR LATIGO TIES
5.75
EDGE
4.00
TOP COAT
1.00
DYE EDGES
3.00
ASSEMBLE
2.00
     TOTAL MINUTES
26.00
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
0.43

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
CROWN STRAP  - 3/4" X 38"
.75
38
28.50
1
CHEEK STRAP  – 3/4" X 15 ½"
.75
15.5
11.63
     TOTAL SQ INCHES
40.13
          25% WASTE SQ INCHES
10.03
               TOTAL SQ FT
0.35


 5/8" BILLET SINGLE PLY HARNESS LEATHER SHAPED CROWN SPLIT EAR HEADSTALL
WITH SEWN DOUBLE HEEL BUCKLES 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
.54
SQ FT MEDIUM HARNESS LEATHER
11.17
6.03
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.)
1.21
     MATERIALS COST
9.14
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
0.48
MATERIALS TOTAL COST
9.62

.48
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
19.20
28.82
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
21.60
31.22
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
24.00
33.62
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
26.40
36.02
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
28.80
38.42

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 SPLIT EAR STRAP
5.50
SEW ON CHEEK BUCKLES AND PUNCH HOLES FOR CHICAGO SCREWS
7.75
EDGE
2.50
TOP COAT
1.00
DYE EDGES
2.00
PUNCH HOLES IN HEAD STRAP FOR CHEEK BUCKLE
1.00
ASSEMBLE
2.75
     TOTAL MINUTES
29.00
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
0.48

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
SHAPED CROWN STRAP  - CUT WITH A PATTERN OR CLICKER DIE - APPROX   3/4" X 28"
.75
28
21.00
2
SHAPED 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
62.00
          25% WASTE SQ INCHES
15.50
               TOTAL SQ FT
0.54



 5/8" BILLET DOUBLED AND STITCHED SHAPED CROWN SPLIT EAR HEADSTALL
WITH DOUBLE HEEL BUCKLES ATTACHED WITH CHICAGO SCREWS
 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
1.23
SQ FT BRIDLE LEATHER OF YOUR CHOICE
10.60
13.04
2
5/8" SS OR SB HEEL BUCKLES
0.79
1.58
4
CHICAGO SCREWS          
0.16
0.64
2
LATIGO TIES
0.44
0.88
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
2.61
     MATERIALS COST
18.75
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
0.99
MATERIALS TOTAL COST
19.73

.88
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
35.20
54.93
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
39.60
59.33
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
44.00
63.73
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
48.40
68.13
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
52.80
72.53
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 CHEEKS ( GLUE, STITCH, AND TRIM  AS NEEDED )
15.00
EDGE
4.75
DYE EDGES
3.25
TOP COAT
1.00
ASSEMBLE
6.00
     TOTAL MINUTES
52.50
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
0.88

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
2
SHAPED EAR BODY CUT WITH CLICKER DIE  APPROX 1 1/4" X 27"
1.25
27
67.50
4
SHAPED CHEEK BODIES CUT WITH CLICKER DIE APPROX 1 1/8" X 16"
1.125
16
72.00
2
5/8" KEEPER STRAPS  1/2" X 2 1/4"
.5
2.25
2.25
     TOTAL SQ INCHES
141.75
          25% WASTE SQ INCHES
35.44
               TOTAL SQ FT
1.23



 5/8" BILLET LINED SHAPED CROWN SPLIT EAR HEADSTALL WITH HEEL BUCKLE
ATTACHED WITH CHICAGO SCREWS AND SHAPED CHEEK 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
.68
SQ FT BRIDLE LEATHER OF YOUR CHOICE
10.60
7.21
.66
4/5 OZ LINING LEATHER OF YOUR CHOICE
10.20
6.73
1
5/8" SS OR SB HEEL BUCKLES                    
0.79
0.79
2
CHICAGO SCREWS
0.16
0.32
2
LATIGO TIES          
0.44
0.88
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
1.44
     MATERIALS COST
17.37
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
0.91
MATERIALS TOTAL COST
18.29

.93
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
37.20
55.49
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
41.85
60.14
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME
46.50
64.79
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
51.15
69.44
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
55.80
74.09

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 CHEEKS ( GLUE, STITCH, AND TRIM  AS NEEDED )
15.00
EDGE
4.75
DYE EDGES
3.25
TOP COAT
1.00
ASSEMBLE
6.00
     TOTAL MINUTES
55.50
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
0.93

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
SHAPED EAR BODY CUT WITH CLICKER DIE  APPROX 1 1/2" X 38"
1.5
38
57.00
1
SHAPED CHEEK BODIES CUT WITH CLICKER DIE APPROX 1 1/4" X 16"
1.25
16
20.00
1
5/8" KEEPER STRAP - 1/2" X 2 1/4"
0.5
2.25
1.13
     TOTAL SQ INCHES
78.13
          25% WASTE SQ INCHES
19.53
               TOTAL SQ FT
0.68
MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
SHAPED EAR BODY CUT WITH CLICKER DIE  APPROX 1 1/2" X 38"
1.5
38
57.00
1
CHEEK BODIES  – CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 15 ½"
1.25
15.5
19.38
     TOTAL SQ INCHES
76.38
          25% WASTE SQ INCHES
19.09
               TOTAL SQ FT
0.66



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