Long leather loops called tunnel loops are attached to the flank cinch as a safety feature to reduce the risk of a rope becoming caught on the flank cinch billets. To shape the loops, wooden wedges are inserted from each end and the dampened leather is formed around the wedges. Once the leather has dried, the leather will retain its shape and flank cinch billets will slide easily into the loop.
After the skirts have been shaped to conform to the underside of the bars, another layer of leather is glued to the underside of the skirt to keep the skirts from curling and distribute the weight of saddle and rider on the horse’s back. Oak-tanned shearling is glued to the bottom, forming a third layer of the skirt. These layers are stitched together around the skirt perimeter, then the edges are trimmed and burnished.
The cantle binding is stitched by hand using a very sharp awl to pierce several layers of leather, a very long piece of strong thread with a needle on each end of the thread. This part of saddle construction probably separates people who would like to make saddles from those who will go on and become saddle makers in the long term. Folks with limited patience could find this process something of a challenge. Once the stitching has been completed, the binding leather is trimmed close to the line of stitching.
When the saddle is finally assembled, the stirrup leathers are stretched and the fenders & stirrup leathers are turned so that the stirrups will be at a comfortable position for the rider.
This ¾ double rigging is ready to be installed on the tree. The rigging is made of two layers of sturdy leather stitched and glued together. The hardware is attached with copper rivets. Each side of the rigging must be a mirror image of the other.
Once the components of the saddle have been completed, the pieces are oiled, buffed and installed on the tree. The strings are attached, stirrup treads are installed and the finished stirrups and choke straps are installed on the stirrup leathers. The latigos are attached to the front rigging rings, and flank cinch billets are attached to the rear dees.