Chapter VI: Cart Collars

In making a cart collar (see Fig. 95) the first part to take in hand is the forewale A; the material for this must always be cut 8 in. longer than double the length of the collar when finished, to allow for shrinkage. Supposing the collar is to be 20 in., the leather must be cut 48 in. long. The leather can be cut from the bellies of gear hides, which come in handy when proper hide is not available. Cut it 7½ in. wide and make the length to meet requirements, and then damp it thoroughly. Stretch it on a flat board by holding one edge with the hand and pulling the other edge with the pincers. Fold it over 2¾ in. all along; adjust the compass by rule to 2¼ in., and mark from the turned side, so that there will be ¼ in. of leather outside the mark on which to stitch the lining. On the opposite side there will be about 2 in. to draw in the body B and stitch the side-pieces. Tack along the mark here and there to keep it in its place.

Make a ten-strand thread, waxing it before and after twisting. This thread must be long enough to stitch all the length, and at least twice as long as ordinary thread. Use strong needles, making about three stitches to the inch; always leave the stitches slack, merely drawing them home, especially for about a foot on each side of the centre. Thus the forewale will bend easier in working round, and the stitches will tighten enough in stuffing. If the leather has an uneven grain, close here and open there, a piece of calico slack may be put inside the forewale A; take care that both sides of it are caught in stitching. This will help to keep it straight even when being stuffed.

The forewale is now ready for stuffing. Having a bundle of rye straw at hand, pull a few handfuls across the knee until the straw is straight; cut the ears off, and then cut the handful of straw in half, and again divide it with the collar knife until about 9 in. long. Place it neatly in a heap near the working-seat on the right-hand side, with the collar rod and mallet lying close by; there must also be a thick, solid block of wood placed on the firm ground in front of the worker’s seat.

The collar-maker must now sit down and mark the centre of the leather with a nick or stitch. The forewale is now placed on the block, and the left foot laid on it, about 2½ in. from the centre, the folded part of the forewale being furthest. Put the other end on the right knee, and, holding the collar rod in the left hand point upwards with the head against the knee, take about half a dozen cut straws, and give them a half twist with both hands. Place the centre of the wisp in the nick of the collar rod and hold it firm with the right hand, the forewale being handled with the left. Put the straw in the forewale and press it down to where the foot is on the block, 2½ in. from the centre; beat the wisp well on the block with the mallet, leather as well, and then put another wisp in from the other end, taking care, when putting in the wisps, that they do not catch those already inside and drive them back; to avoid this, beat well after each wisp has been put in, and when the iron reaches them raise the point a little. Continue to work in this way, putting in wisps alternately at each end until the forewale is as hard as it can be made. When the straw seems firm enough not to move, the wisps can be knocked in instead of being pushed by hand. See that they go into the centre of the straw. Push the straw and rod down the centre as far as possible; turn the forewale and the rod with the point upwards, knocking the wisp in firmly against the collar block in front.

Repeat the process from the other side, and so on until all is as hard as a piece of wood. To shape and round the collar it must be continually turned round the knee, turning one side to the right and the other to the left hand. This operation is repeated after every one or two wisps are put inside; take care that the forewale does not get straight. When turned enough, three or four wisps may be put into each side before changing; but both sides must be shaped alike.

When approaching the top, shape it inwards a little in the same way as it was turned; fill with straw until the top is quite firm, and then place it flat on the block, beating it well into shape with the round mallet, and holding it down with both knees at one end while shaping the other. Now damp it, and turn it backwards a little at the top on both sides; stitch both points firmly together with waxed twine and collar needle and hand iron, cutting a little off when necessary to bring it to the right length.

To make a pipe collar, follow all the above directions and proceed as below. Obtain a piece of iron 9 in. long, ½ in. in diameter, and having a sharp point; in the middle it must be shaped half-round, with the points turning a little outwards and upwards. Put straw around it, tying it as tightly as possible to within 2 in. from each point, and let the straw at each end be of different lengths, a few inches longer than the points of the iron, so that it will splice well when stuffing is commenced. Add straw, and tie again until the straw around the iron is the right size, then place it in the centre of the forewale, and stitch as tightly as possible, pulling the stitches well; make sure that it fills the forewale well, but having passed this part, leave the stitches slack. Now stitch from end to end, and stuff from each end as in the other case, remembering to splice them well where the iron ends; the sharp point will not be much of a hindrance. Finish as with the other collar.

In making the body of the collar, cut the lining to Fig. 96, and in any required size; 14 in. is about the average at the draught when the strain of pulling is on the collar. Cut a leather throat-piece about 2 in. wide at the base, and widening out to 3½ in. in a sweep to the top. Stitch the narrowest end of the lining, which is about 4½ in. deep, to the sweep of the throat-piece, turning in a little of the linen or woollen check to make the part under the stitches strong.

The narrowest part of the centre of the throat-piece must now be tacked to the exact centre of the collar by the stitches, putting the edge even with the rim of leather running inside from the stitches.

Add another tack without pulling at the lining, but leaving it rather slack from the centre, just at the part where the forewale begins to run straight upwards. Another tack is now placed within 5 in. from the top on both sides, and the lining pulled tightly to there from the bottom, the edges being turned in all round.

Basil is employed for part of the lining in some localities; about 6 in. is measured from the top of the collar. A pattern of the lining must be cut out of brown paper, and then the basil can easily be made to fit the shape of the linen lining; the basil must be whipped in with white linen thread and the linen turned in a little under the stitch, being rubbed flat afterwards. The lining being ready, make a four-cord thread of black-wax, cut it in two, and thread a harness needle with half. Having a suitable awl, whip the lining in all round through the leather rim above the stitches inside the forewale; the stitches of course must be inside, and should be well rubbed. Everything is now ready for making the body. Wax some strong twine or make a long beeswax thread, with four or five strands, 3½ yds. long, and have another about 1½ yd. long with six or seven strands.

Now a strong old strap, 1 ft. long, with a buckle is wanted; this is called the throat strap. The hand-iron, a medium-sized collar needle, seat-awl, scissors, and collar knife being placed near at hand, get a bundle of rye or wheat straw, preferably rye, and place it straight together by the side of the stool, with a sheet of drummed flock or basket of carded flock all within reach. As during work the legs are placed inside the collar, making it awkward for the operator to move, it is well to have handy a flat-headed mallet besides the collar mallet. Thread the collar needle with the shortest thread and hang it close by, and having pulled a big handful of straw from the bundle, sit down and put the right leg through the collar lining, the throat being placed upwards.

Place the middle of the handful of straw exactly in the centre of the throat-piece, between it and the forewale; then take the needle and thread it, the hand-iron being in the right hand. Make a stitch from the centre of the throat over the straw to the big margin of leather on the other side; make another stitch at the same place to keep the throat in the centre, and more stitches, about 1½ in. apart, for about 6 in. up one side from the middle towards the left. Fasten the thread and cut it, turn the collar with the other side facing you, and stitch it again on this side exactly like the first, taking great care to make both sides similar in shape and size.

Take the stuffing-stick and fix a wisp of straw on the point, beating it along to the centre of the straw and a little beyond the centre of the throat. Place a similar one on the opposite side, and so continue until the bottom part is firm and hard. Now lay it on the block, with the lining on the top, and pull the lining outwards as much as possible. Hold it by the knees, one on each side, and beat the throat outwards as far as possible with the round collar mallet. Put the throat strap round it and the forewale, pulling it as tightly as possible to keep it in position while making the other part. Now take a wisp of straw, large enough to fill the body of the collar pretty well, cut it square at one end, so as to get almost the full bulk at the section, and see that it is long enough to go the full length of the collar body.

Wrap a piece of hemp five or six times round the part just cut, making it firm for about 6 in. along, and somewhat pointed. Run the long thread through the needle, and put both knees through the collar with the lining towards you. Open the lining flat as it lies on the knee and raise the straw issuing from the throat so as not to be in the way; then cut a piece of drummed flock to the same size as the lining, to come within an inch or so of the edge. Take care to place it level in all parts, reaching well down towards the throat and forewale. Cut another handful of straw and put it over the flock opposite the draught and as near as possible to the forewale.

Open the straw running from the throat in the centre, and put the long tied wisp inside, ramming it as near as possible to the throat; pull the lining over the straw from the top to the bottom, and then pass the seat-awl through the lining and leather to fasten the top. Turn the collar the other way about, put both legs in again, and begin to draw in the lining where the bottom stitching left off.

Now lace it from bottom to top, running the needle from lining to leather and leather to lining till finished. Draw the stitches as tightly as possible, pulling each to tighten the other, as in lacing a boot. So far, the collar is neither hard enough nor shapely enough; the straw must therefore be beaten down between the lacing. To do this, the mallet must be grasped round the handle close to the head, and the straw struck as hard as possible with the handle.

Having improved the shape of the collar, begin to tighten the lacing again from end to end, keeping the desired shape constantly in mind. If the collar is not firm enough, begin work at the bottom, ramming down some wisps towards the throat from between the stitches, and continue this until the draught is reached, shaping as well as stuffing. It may be hardened, from the draught up to the top, by driving some wisps from the extreme top, and shaped by tightening or slackening the lacing, as the work demands.

Great attention must be given to shaping, for a well-shaped body is very important from the point of view of both utility and appearance; it should be graceful and rounded at the bottom and somewhat flat at the draught, gradually growing narrow towards the top. At the extreme tip, however, the collar should be rather full, with extra flock to ease the neck. Work in the same manner with the other side, using as nearly as possible the same amount of flock and straw; take care to obtain the same shape and size.

If any lumps can be felt in the flock, loosen and level it with the seat-awl by stuffing it off or on as required; beat it slightly all round to give it a smooth appearance. Cut the straw at the top, turning the lining down out of the way; beginning close to the forewale, cut it slanting upwards a little towards the back. Make two or three long stitches in each side through the lining on both sides and the straw to pull the linings together. Then stitch together the two sides, drawing the lining over the outer side; run the stitches through from side to side and cut the spare lining at the top; this completes the work. Trim the points of the forewale previously stitched, and cut them into a neat point, which should be neither long nor sharp.

Having cut a piece of soft leather, form it into a cap reaching low enough to cover the stitches that join the point on each side; stitch the front with a welt between the edges long enough to reach the back under the forewale, so that a stitch can be put through it there when stitching the cap. This last must be long enough to come over the point of the body behind; damp the cap and put it in its place. Take a lace and the collar needle, draw it down tightly into the hollow between the body and the forewale, then stitch through it, burying the welt underneath to fasten the cap in front by a stitch.

The other part must be stitched with a lace all round over the top of the body; make the point of the forewale very prominent to hold the hame strap.

Two 1½-in. straps, 18 in. long, must now be cut; race the edges and blacken them, point them for the buckle, and punch four holes in each, and another hole in each corner at the opposite end and one in the centre 2½ in. from the end. The four holes in the forepart are to fasten the buckles to the crupper or cart-saddle and the others to stitch to the collar. Place one on each side of the collar down to the forewale 5 in. from the top. Fasten them with lace by stitching through the hollow between the forewale and collar body, putting two stitches through and through to the other side; then send the collar needle in the direction of the other hole in the centre of the strap, and make one stitch from each side of the strap through this hole; fasten the lace well and cut it.

Pieces of leather of the shape shown by Fig. 97 are now required to cover the side of the body. The pattern can be cut out of brown paper according to the made body and kept for other work. Cut the paper close to the rim all round to cover the body full in all parts outside, but a little wider and pointed at the top to keep rain-water off and give a good appearance. Cut one side only at a time, and, as the two sides join in the centre at the top and bottom, cut the top slanting downwards towards the forewale to the same shape as the body, and line the top for about 1 ft. downwards on each side with firm leather; shave it on the inner side and bottom.

The pieces need not be so wide as the side-piece; half its width or a little more will do. Make three rows of stitching, and join them together at the lower part along the lined part; the distance between the rows should be about 1 in., with nine stitches per inch. Rub the side-pieces and blacken them; crease two rows with a screw-crease all round the outer side not stitched. When cutting, take care to have the best part under draught. Join the two sides together at the top with stitch after stitch from one to the other, thus drawing them close end to end.

Crease and prick a 1¼-in. piece of leather, cutting it to the same length as the joint, and thinning it towards the collar end; the other outer end must be shaped to the point of the joint. Now tack the piece and stitch, keeping it quite over the centre of the joint, and making the stitches exactly at the same distance on both sides; it is well to put a bit of thin lining underneath the stitches. Damp the side-pieces well in water, and have a long lace ready to run the side-piece in; damp and grease it, and have it long enough to go all round the collar if possible, with sufficient to spare for fastening.

Take out the side-pieces, beat the water from the leather, and fasten the pieces to the centre on top with a big strong awl or seat-awl. Pull them together as tightly as possible from top to bottom; let them overlap about 3 in. at the bottom, shave the leather down a little here, and fix the pieces in place with the awl. Then see that they are in the right position, not too near nor too far from the forewale; put an awl on each side near the draught to keep them in position there.

Begin lacing them in at the throat-piece, making the stitches 2 in. or 2½ in. apart, at about the same distance from the edge all round; be sure to catch the lining underneath with each stitch. Then take another long lace and pull it in at the throat; draw it close to the forewale all round till the point of commencement is reached, running a stitch over the edge of the side-piece, and catching the leather everywhere by the forewale; the stitches should be about 1½ in. apart.

Some harness makers run a piece of leather about 13 in. under the draught, fasten it with a few stitches to the collar body in the lower part, and spot with lace to the side-piece all round the top part; coarse flock, or anything which will keep the chains from the horse’s shoulder when pulling, being employed for stuffing; but this will not be necessary if the body of the collar is well made. Others make the side-piece without lining, using instead a round piece of leather with canes round the rim, covering them with leather stitched on both sides to protect the shoulders and collar from wet. They are stitched with lace to the collar.

Experience, however, has demonstrated that neither the horse nor the collar is any the worse without such a device. In other localities the housing and side-piece are cut in one piece—a poor imitation of a Scotch collar—and stiffened all round with cane; this involves a great waste of leather, and is unnecessary.