For small orders, lengths of elastic are hand cut with a sharp pair of scissors using notches marked up on our cutting tables. For larger orders, the rolls of elastic are mounted onto large spindles and we use the Minor press (similar to the Major press) fitted with a blade to cut the elastic.

Tabs are then punched out, first using the scrap leather left over from the belt leather blocking process. A specialised die is attached to our swing arm clicker press and punches out the small triangles used to make our Y-back braces or longer 'finger-like' pieces for our leather tab ends.

To make our Y-back braces, two pieces of leather triangles, back to back, are used to join two long lengths and one short length of elastic. We have a specially engineered sewing machine programmed to just sew the triangle on. To make our X-back braces, two long elastics are simply fed through a ‘butterfly clip'. 

Metal adjusters are then fed along the elastic. These components allow the user to resize and fit themselves perfectly with braces.

Ends are then sewn onto the elastic. We have two different ends: pressed metal clips or a traditional, leather button end. The leather button end tabs are riveted onto a metal loop which is then sewn onto the braces.

We always joke that this is the hardest process involved, and during peak times sometimes involves staff from the office to assist with packing! There is a true art to wrap braces around a board and slide them into the box.

Braces move through this process where barcodes and other information such as back type are included before they are sent out.

Like with our handcrafted belts, braces are then consolidated into orders with our other accessories and carefully wrapped then packed into boxes or jiffy bags. The order is confirmed in its entirety and the final quality control check is made.  

Using the information provided by the picking and packing team, our invoicing clerk weighs, invoices and books the order in for delivery.