SC: Can you describe your process?
B: The whole process is very much bespoke and hand crafted. Here is a list and description of the steps typically involved in doing a perforated saddle recover. It’s not comprehensive and doesn’t include some of my secret techniques.
1. Correspond with the customer to discuss design brief. Usually this will include some visuals of the bike that the work will be applied to.
2. Design: I render a small range of design options for the customer to consider and further develop design if needed.
3. Saddle stripping: I spend a lot of time removing the factory cover from saddles, taking great care to avoid any damage to the foam padding. On some saddles this can be easy and other very difficult.
4. Pattern making: A large part of my work is moulding the leather to the required 3D form. The rounder and more complex a saddle shape the more leather shape forming that will need to be done. I like to keep seams and stitching to a minimum, however complex shaped saddles require complex pattern making with gussets and panels. At the moment I am really enjoying this complex pattern making.
5. Cutting and perforating: From the patterns I cut the leather and make any perforations by hand. That is with a mallet and a single hole punch!
6. Construction: Coloured leather underlays are prepared to be glued behind any perforations to show through the small holes. Then any panels are seamed together by hand using two needles and a single waxed thread. Seams are finished and glued as flat as possible.
7. Moulding and gluing: The leather is moulded to shape over the saddle form and then glued directly onto the foam with a contact adhesive.
8. Finishing: The edges are finished in a variety of different ways depending on the design and manufacture method of the original saddle.