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WESTERN SHAPED BROWBAND
HEADSTALLS
TABLE OF CONTENTS
The designs and styles of shaped browband headstalls is only limited by one's imagination.  Therefore, four 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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 5/8" SINGLE PLY HARNESS LEATHER SHAPED BROWBAND 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
.97
SQ FT MEDIUM HARNESS LEATHER
11.17
10.83
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" TUCK LOOPS OR LATIGO TIES
0.13
0.26
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
2.17
     MATERIALS COST
15.92
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
0.84
MATERIALS TOTAL COST
16.76

.70

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
28.00
44.76
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
31.50
48.26
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME


35.00

51.76
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
38.50
55.26
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
42.00
58.76
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
EDGE
6.00
TOP COAT
1.00
DYE EDGES
5.00
MAKE-UP BROWBAND
4.50
PUNCH HOLES IN HEAD STRAP FOR CHEEK BUCKLE
1.00
SEW ON CHEEK BUCKLES AND PUNCH HOLES FOR CHICAGO SCREWS
7.75
SEW ON THROAT LATCH  BUCKLE AND PUNCH HOLES FOR BUCKLE                    
5.25
ASSEMBLE
5.00
     TOTAL MINUTES
42.00
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
0.70

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
CROWN STRAP  - 5/8" X 28"
.625
28
17.50
1
BROWBAND STRAP  -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 24
1.25
24
30.00
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
111.50
          25% WASTE SQ INCHES
27.88
               TOTAL SQ FT
0.97



 5/8" SINGLE PLY HARNESS LEATHER  SHAPED BROWBAND 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
.97
SQ FT BRIDLE LEATHER OF YOUR CHOICE
11.17
10.83
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.)
2.17
     MATERIALS COST
16.88
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
0.89
MATERIALS TOTAL COST
17.77

.66

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
26.40
44.17
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
29.70
47.47
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME


33.00

50.77
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
36.30
54.07
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
39.60
57.37
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
EDGE
6.00
TOP COAT
1.00
DYE EDGES
5.00
MAKE-UP KEEPERS
3.75
MAKE-UP BROWBAND
4.50
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
5.00
     TOTAL MINUTES
39.75
     TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
0.66

MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
CROWN STRAP  - 5/8" X 28"
.625
28
17.50
1
BROWBAND STRAP  -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 24
1.25
24
30.00
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
111.50
          25% WASTE SQ INCHES
27.88
               TOTAL SQ FT
0.97


 5/8" DOUBLED AND STITCHED BRIDLE LEATHER SHAPED BROWBAND 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
1.78
SQ FT BRIDLE LEATHER OF YOUR CHOICE
10.60
18.87
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
1.28
2
5/8" TUCK LOOPS OR LATIGO TIES
0.13
0.26
MISC SUPPLIES  @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
3.77
     MATERIALS COST
26.52
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
1.40
MATERIALS TOTAL COST
27.92

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
79.12
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
57.60
85.52
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME


64.00

91.92
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
70.40
98.32
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
76.80
104.72


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
2
CROWN STRAP  - 5/8" X 28"
.625
28
35.00
1
BROWBAND STRAP  -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 24
1.25
24
30.00
1
BROWBAND LINER STRAP  -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 12.5
1.25
12.5
15.63
2
THROAT LATCH STRAP  - ½" X 44"
.5
44
44.00
4
CHEEK BODIES   CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 15 ½"
1.25
15.5
77.50
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
205.38
          25% WASTE SQ INCHES
51.34
               TOTAL SQ FT
1.78
 5/8" LINED BRIDLE LEATHER SHAPED BROWBAND 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
.97
SQ FT BRIDLE LEATHER OF YOUR CHOICE
10.60
10.28
.94
4/5 OZ LINING LEATHER OF YOUR CHOICE
10.20
9.59
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.)
2.06
     MATERIALS COST
25.81
PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
1.36
MATERIALS TOTAL COST
27.16

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
78.36
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 45.00  PER HOUR
57.60
84.76
     HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
    NATIONAL AVERAGE HOUSEHOLD INCOME


64.00

91.16
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT  A SHOP RATE OF  $ 55.00  PER HOUR
70.40
97.56
    HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF  $ 60.00  PER HOUR
76.80
103.96
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
BROWBAND STRAP  -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 24
1.25
24
30.00
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
111.50
          25% WASTE SQ INCHES
27.88
               TOTAL SQ FT
0.97
MATERIALS LIST
NO
DESCRIPTION
WIDTH
LENGTH
TOTAL
1
CROWN STRAP  - 5/8" X 28"
.625
28
17.50
1
BROWBAND STRAP  -  CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 24
1.25
24
30.00
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
     TOTAL SQ INCHES
108.25
          25% WASTE SQ INCHES
27.06
               TOTAL SQ FT
0.94


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