Step 1 – Patterns are cut out by hand
Step 2 – All leather patterns are stitched around the edges to prevent fraying – there are two patterns cut, the vamp and the quarters which meet at the ankle.
Step 3 – Leather is stretched by applying heat. This is to form the shape of the boot and ensure that the boot structure stays in the correct shape and does not loosen too much with wear.
Step 4 – Soles and heels are cut from leather.
Step 5 – The toe is moulded into our almond shape. We always manufacture boots using an almond toe as this is the traditional shape of Chelsea boots and are a more flattering shape.
Step 6 – A thick wax is threaded around the sole. This is used for strength and also for flexibility in the sole.
Step 7 – The sole is filled with cork for insulation and comfort. Cork is the most traditional material to be used in the process as it is comfortable and also light. Cork has a lot of natural benefits as it is water resistant and moisture wicking. The cork also thermoforms to the feet to create a comfortable mould to match your feet.
Step 8 – The sole is stitched on using Goodyear welting. This is the most traditional method of boot construction by stitching a specially prepared piece of leather to the ribbing that is bonded to the insole. This welt is then stitched to the sole holding the sole in place. This method of construction is expensive, time consuming and requires highly skilled craftmen.
Step 9 – Polish the soles and outer contour of the soles.
Step 10 – The soles are varnished and ready for wear!