Saddle Panels - Part 2: Felt Foam vs. Wool

Felt Foam Panels

The basic components of this panel style are felt, foam and leather. The Felt is the shell or basic structure of the panel. It offers the basic form that the panel is constructed on. Next, there is usually a small foam bolster, or wedge, that is added to the cantle area to add some appropriate shape and thickness. Then the foam layer is added. This foam layer consists of several different types of foam based on the manufacturer’s specifications. You will often see harder closed cell foam, foam rubber and sometimes a combination of several different types. At Beval Saddlery, we use natural latex foam in the majority of our saddles and also for any adjustments or customizing that we do using foam. The latex is a very high quaility natural product and is quite expensive. The entire panel construction is then covered with a leather lining. The leather is usually soft calf-type leather that molds well to the shape and also adds to the softness of the panel. This leather is stitched to the felt shell, the layer mentioned earlier, with a whip or basting stitch. Most of the construction in this type of panel is done completely by hand.


Wool Stuffed (flocked) Panels

The structure of this panel consists of a leather shell, which is lined with canvas material (to give it some stiffness) and a leather lining. The facing (piping) usually found on the front edge of the flap, and between the panel and the cantle of the saddle, is built into this panel. The sweat flap and blocks, if needed, are added as part of the panel construction. Gussets are added in the cantle or pommel area if needed. Basically, this type of panel is like a big shaped bag attached to the bottom of the saddle and stuffed with loose wool flocking. The construction of this type of panel is a bit more complicated since it consists of as many as 10 different components. The panel is also made inside out so that all the seams can be sewn without showing on the finished product. Before final assembly and stuffing, the panel is turned right side out.

Up Next! "Saddle Panels - Part 3: Comparing & Adjusting Panels"