 |
 WESTERN SHAPED BROWBAND HEADSTALLS
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TABLE OF CONTENTS
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The designs and styles of shaped browband headstalls is only limited by one's imagination. Therefore, four generic examples are listed.
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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
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BRIDLE LEATHER
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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
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MATERIALS LIST AND COSTS – Based on average costs and times for a saddle maker with 3/5 years of experience
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AMOUNT
|
DESCRIPTION
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COST
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TOTAL
|
.97
|
SQ FT MEDIUM HARNESS LEATHER
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11.17
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10.83
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2
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5/8" SS OR SB HEEL BUCKLES
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0.79
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1.58
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1
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1/2" SS OR SB HEEL BUCKLE
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0.76
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0.76
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2
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CHICAGO SCREWS
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0.16
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0.32
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2
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5/8" TUCK LOOPS OR LATIGO TIES
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0.13
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0.26
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MISC SUPPLIES @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
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2.17
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MATERIALS COST
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15.92
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PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
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0.84
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MATERIALS TOTAL COST
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16.76
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.70
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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 }
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SHOP RATE TOTAL
|
MATERIALS
&
SHOP RATE
TOTAL
|
|
HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF $ 40.00 PER HOUR
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28.00
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44.76
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HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF $ 45.00 PER HOUR
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31.50
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48.26
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HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
NATIONAL AVERAGE HOUSEHOLD INCOME
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35.00
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51.76
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HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF $ 55.00 PER HOUR
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38.50
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55.26
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HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF $ 60.00 PER HOUR
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42.00
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58.76
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TIMES – Based on average times for a saddle maker with 3/5 years of experience
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PROCESS
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TIMES (minutes)
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CUT
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2.50
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LEVEL (SPLIT) Optional
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1.00
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MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, SKIVE, AND FINISH ENDS
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3.00
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EDGE
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6.00
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TOP COAT
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1.00
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DYE EDGES
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5.00
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MAKE-UP BROWBAND
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4.50
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PUNCH HOLES IN HEAD STRAP FOR CHEEK BUCKLE
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1.00
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SEW ON CHEEK BUCKLES AND PUNCH HOLES FOR CHICAGO SCREWS
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7.75
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SEW ON THROAT LATCH BUCKLE AND PUNCH HOLES FOR BUCKLE
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5.25
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ASSEMBLE
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5.00
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TOTAL MINUTES
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42.00
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TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
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0.70
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MATERIALS LIST
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NO
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DESCRIPTION
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WIDTH
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LENGTH
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TOTAL
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1
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CROWN STRAP - 5/8" X 28"
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.625
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28
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17.50
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1
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BROWBAND STRAP - CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 24
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1.25
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24
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30.00
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1
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THROAT LATCH STRAP - ½" X 44"
|
.5
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44
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22.00
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2
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CHEEK BODIES – CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 15 ½"
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1.25
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15.5
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38.75
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1
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1/2" KEEPER STRAP - 1/2" X 2"
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0.5
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2
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1.00
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2
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5/8" KEEPER STRAP - 1/2" X 2 1/4"
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0.5
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2.25
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2.25
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TOTAL SQ INCHES
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111.50
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25% WASTE SQ INCHES
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|
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27.88
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TOTAL SQ FT
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|
|
0.97
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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
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SQ FT BRIDLE LEATHER OF YOUR CHOICE
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11.17
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10.83
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2
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5/8" SS OR SB HEEL BUCKLES
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0.79
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1.58
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1
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1/2" SS OR SB HEEL BUCKLE
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0.76
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0.76
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8
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CHICAGO SCREWS
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0.16
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1.28
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2
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5/8" TUCK LOOPS OR LATIGO TIES
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0.13
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0.26
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MISC SUPPLIES @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
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2.17
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MATERIALS COST
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16.88
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PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
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|
0.89
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MATERIALS TOTAL COST
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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
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26.40
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44.17
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HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF $ 45.00 PER HOUR
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29.70
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47.47
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HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
NATIONAL AVERAGE HOUSEHOLD INCOME
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33.00
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50.77
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HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF $ 55.00 PER HOUR
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36.30
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54.07
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HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF $ 60.00 PER HOUR
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39.60
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57.37
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TIMES – Based on average times for a saddle maker with 3/5 years of experience
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PROCESS
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TIMES (minutes)
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CUT
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2.50
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LEVEL (SPLIT) Optional
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1.00
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MARK HOLES FOR BUCKLES, BUCKLE SLOTS, CHICAGO SCREWS, SKIVE, AND FINISH ENDS
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3.00
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EDGE
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6.00
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TOP COAT
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1.00
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DYE EDGES
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5.00
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MAKE-UP KEEPERS
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3.75
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MAKE-UP BROWBAND
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4.50
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PUNCH HOLES IN HEAD STRAP FOR CHEEK BUCKLE
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1.00
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PUNCH HOLES FOR CHICAGO SCREWS ON CHEEK STRAPS
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4.25
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PUNCH HOLES FOR CHICAGO SCREWS THROAT LATCH BUCKLE AND PUNCH HOLES FOR BUCKLE
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2.75
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ASSEMBLE
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5.00
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TOTAL MINUTES
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39.75
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TOTAL HOURS OF LABOR NEEDED TO MANUFACTURE ITEM
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0.66
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MATERIALS LIST
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NO
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DESCRIPTION
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WIDTH
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LENGTH
|
TOTAL
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1
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CROWN STRAP - 5/8" X 28"
|
.625
|
28
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17.50
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1
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BROWBAND STRAP - CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 24
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1.25
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24
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30.00
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1
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THROAT LATCH STRAP - ½" X 44"
|
.5
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44
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22.00
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2
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CHEEK BODIES – CUT WITH A PATTERN OR CLICKER DIE - APPROX 1 1/4" X 15 ½"
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1.25
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15.5
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38.75
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1
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1/2" KEEPER STRAP - 1/2" X 2"
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0.5
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2
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1.00
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2
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5/8" KEEPER STRAP - 1/2" X 2 1/4"
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0.5
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2.25
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2.25
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TOTAL SQ INCHES
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|
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111.50
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25% WASTE SQ INCHES
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|
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27.88
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TOTAL SQ FT
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0.97
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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
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MATERIALS LIST AND COSTS – Based on average costs and times for a saddle maker with 3/5 years of experience
|
AMOUNT
|
DESCRIPTION
|
COST
|
TOTAL
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1.78
|
SQ FT BRIDLE LEATHER OF YOUR CHOICE
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10.60
|
18.87
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2
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5/8" SS OR SB HEEL BUCKLES
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0.79
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1.58
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1
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1/2" SS OR SB HEEL BUCKLE
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0.76
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0.76
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2
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CHICAGO SCREWS
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0.16
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1.28
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2
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5/8" TUCK LOOPS OR LATIGO TIES
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0.13
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0.26
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MISC SUPPLIES @ 20% (THREAD-RIVETS-DYE-OIL, ETC.)
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|
3.77
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MATERIALS COST
|
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26.52
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PROFIT OR RETURN ON INVESTMENT ON MATERIALS USED
|
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1.40
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MATERIALS TOTAL COST
|
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27.92
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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
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51.20
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79.12
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HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF $ 45.00 PER HOUR
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57.60
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85.52
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|
HOURS OF LABOR AT A SHOP RATE OF $ 50.00 per HOUR
NATIONAL AVERAGE HOUSEHOLD INCOME
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64.00
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91.92
|
|
HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF $ 55.00 PER HOUR
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70.40
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98.32
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HOURS OF LABOR NEEDED TO MANUFACTURE ITEM AT A SHOP RATE OF $ 60.00 PER HOUR
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76.80
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104.72
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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
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MAKE-UP BROW ( GLUE, STITCH, AND TRIM AS NEEDED )
|
8.00
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MAKE UP CHEEKS ( GLUE, STITCH, AND TRIM AS NEEDED )
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15.00
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MAKE-UP THROAT LATCH ( GLUE, STITCH, AND TRIM AS NEEDED )
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6.00
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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
|
|
Copyright 2005 - 2016 American Saddle Makers Association, Inc.
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