Bricycle brings up a good point, "ruined many a good saddle." I've screwed a few up, but I've never ruined any of them. I just start over, learning from my mistakes. You may ruin your piece of leather or fabric by not cutting it big enough. [ this only becomes evident when pulling your tabs of covering over the pan's edges] Make double sure your piece of material is large enough. I've never ruined a saddle. I just do it over. Here's a saddle I will do over this winter.
Looks good, I got the leather tight. What's wrong with it? Look closely. See that tiny scratch a couple inches up, on the right? The leather was too old and is starting to rot. I've run into this before, and it only becomes apparent when stretching the leather over the seat pan. look at how the top finish starts separating when pulled tight, especially at the horn. Give your leather a couple real hard pulls before starting your project. If it starts to separate or easily rip, it's too old or too thin.
If you have an old piece of leather, even if it's "new" leather, that has been sitting around for years, it deteriorates if stored incorrectly. I know a few things about leather. During high school, I was in a work program. I got out of school at 1:00 and worked as a leather cutter in a small printing and novelty company. They made small things out of leather, and I cut them, by hand, using a maul . For over two years, I worked with half hides over large maple cutting blocks. Cutting by hand, using sharp metal dies. There's a machine called a "clicker" that does this job now. The shop I worked in had some very ancient machinery, that I know later got scrapped. A leather company would give their left nut to have it now. That was back in 1966, when old bikes and old machinery was viewed as "scrap metal, to get rid of. I'm only familiar with two types of hides. Horse, cattle. Chrome tan and veg tan. Veg tan is generally cow hide, and usually is the most expensive. It's thicker, stronger, and extremely elastic, and workable when wet. It's used for strong belts, horse saddles and harnesses. It accepts tooling and is easily recognizable. When you see intricate designs cut and stamped into leather, it's veg tan. The tanning process of veg tan is the oldest. Sometime, way back when, primitive man found out that animal hides could be used for clothing, they found ways to preserve [tan] it. Trial and error, the oldest teacher. It got it's name from the vegetable compounds used in this process. In Europe, Northern Asia, and North America, bark from oak trees was primarily used. It's still used today, but has been mostly replaced by other less costly compounds. Producing vegetable tan leather is a long and costly process. It uses lots of fresh water and creates hazardous waste. As to be expected, China and Mexico are big producers of tanned leather. It's less costly, but, inferior to leather produced in the United States. If you have worked with new hides, as I once did, you easily recognize "good" leather. Chrome tan leather uses chemicals in the tanning process, and is much easier and less costly to make. Your, furniture, jackets, purses and belts are usually chrome tan. Comes in every color imaginable. Different thicknesses, and can embossed to resemble other species hides. The problem with chrome tan is, it does not accept water. It will not form like veg tan. Untreated veg tan would make a poor rain coat. When wet, veg tan can be easily pulled, molded and "formed." Chrome tan leather is what it is. Not much you can do to make it more workable. I've found that when it's very warm, it is much easier to work with. Especially on a winter day, as my shop is generally pretty cold. As far as my "criteria" for my free leather? I carry a razor knife in my truck and car. If I see an old chair on the curb, that looks like it's leather, I first stop and see if the home owner is out. If I'm alone, I hack into the chair and see if it's truly leather, and not "pleather" or some other man made fabric. I've had homeowners come out and start yelling at me when they see me cutting into the chair that they placed out for the garbage guy. Sometimes I have gone back later to do my "cutting." I've found that leather from chairs is usually perfect for saddles. Sometimes though, it's too thin. Leather jackets are usually made up of smaller pieces of leather. It's generally too thin and is prone to tear when over stretched. I've never found a coat with pieces big enough to do a boy's saddle. One other point, that I thought I had addressed earlier, but apparently I didn't make clear enough. This isn't for the finicky. This post was intended for the "weekend" hobbyist that wants to do something by themselves, that's easy and definitely not costly. It's for saddles generally produced after 1939. Veg tan leather was generally not used on any saddles after this year. Chrome tan, oilcloth and leather look-a -likes are used on the 40's and 50's saddles, and generally have two pans, and are the easiest to do. This JC. Higgins saddle I covered is a two pan saddle.
The leather is used, so they are imperfections in the finish, but these are for riders, not show bikes.
I purposely used a worn piece of couch leather on this saddle, positioning the leather on it to resemble normal saddle wear.
The pre-war saddles are often single pan, and have sewn edges and seams. I haven't tackled any of those yet, but I plan to. I'll keep you folks posted. On those, I will use veg tan leather. Sewing is a whole new ball game. In the meantime, any of you folks that do the older saddles, and aren't a "hack' like me, please give us a step by step tutorial, with lots of photos. Share your knowledge. If you don't want to use leather, Ann's Fabrics and Hobby lobby have a large selection of other materials. Keep having fun! On a side note, after the leather company, I went to work at National Lead Co, at the old Halsted plant on Chicago's far south side. They made lead paint and lead products there since 1906 or 07. That's a story in it's self.