Category: History of Panel Saddles

Flex Panel Saddles: Addressing the Misconceptions

The Discussion That Sparked This Post

Recently, I engaged in a brief discussion in a Facebook group regarding misconceptions that surround the flexible panels that are used on Evolutionary Saddles. The group’s admin raised concerns about the saddle’s functionality, comparing it to conventional saddles with their rigid trees. They cited the long history of poorly engineered panels that broke down and caused harm to horses.

These concerns are valid, but dismissing the evolution of the concept entirely due to past failures is a missed opportunity.

My Experiences

As a saddler who rides in my own creations, I’ve witnessed firsthand the benefits of Evolutionary Saddles and the System X panel design. Here, I’ll address the misconceptions and explain why this innovation is worth considering.

An Invitation to Experience the Difference

I’ve invited skeptics to ride with me in one of my saddles or, if distance is an issue, to try one if they ever get the chance. Evolutionary Saddles are engineered with both horse and rider in mind, offering a blend of comfort, functionality, and safety.

Early Encounters with Flex Panel Saddles

Over 35 years ago, I encountered my first flex panel saddle at the Midwest Horse Fair. The concept was intriguing but flawed. Early designs, such as the first-generation Ortho-Flex saddles, were crude. They featured single-layer delrin panels bolted to a fixed tree, which failed to redistribute weight effectively or adapt to a horse’s motion. These shortcomings led to skepticism about the entire category of flex panel saddles.

The Evolution of the System X Panel

Cathy Tauer’s innovative approach revolutionized the concept of panel saddles. She asked a crucial question: Why can’t we do better? The result was the System X panel, which redistributes weight across a larger surface area and accommodates a horse’s natural movement. This design eliminates the pointed pressure and rigidity of earlier models.

The System X panel uses layers of delrin, a material known for its durability and memory. Each layer is designed to distribute weight progressively, while the front of the panel features “fingers” that allow the scapula to move freely. This ensures both comfort and performance for the horse.

My Personal Journey with Evolutionary Saddles

When I purchased my first Evolutionary Saddle in 2014, I was skeptical but hopeful. After riding over 20 horses of various shapes and sizes that summer, I was convinced. The saddle fit consistently well, allowing horses to move freely with no signs of discomfort. Even cinchy horses became more relaxed after just a few rides.

A major test came during a week-long horse drive in Idaho. My riding companion and I used Evolutionary Saddles, while others relied on conventional saddles. By the end of the week, our horses were the only ones without sore backs.

Addressing Common Concerns

Some riders worry that panel saddles create a “perched” feeling, distancing them from the horse. My experience has been the opposite. The deep seat and customizable options, such as a soft seat for a narrower twist, provide a secure and close connection.

Conclusion

Evolutionary Saddles are designed for riders who prioritize their horse’s comfort and their own. Whether you ride for pleasure, endurance, ranching, or competition, a well-fitting saddle enhances the experience for both horse and rider.

Dismiss the myths and discover the innovation of the System X panel. Your horse deserves a saddle that works with them, not against them. If you’re curious, reach out or explore our website to learn more.

This is what Evolutionary Saddles focuses on, function, form and comfort for both horse and rider.

Companies that are out of business or re-marketing

There have been a lot of changes in the flexible panel saddle industry in the past 40+ years. Here is a brief synopsis of what has happened and where things stand today.

2023 – The Status of the Flexible panel saddle makers

Rocking R, Watson Brothers Saddles, Ozark Mountain Saddles and Saddle Ranch are all out of business. 

Eldorado Saddle & Tack, which is a combination of Amera-Flex, Ameri-flex, 7E, Easy Slide and Eldorado saddles, and American-Flex Saddles of Germany are now made by DK Saddlery.  Which have used photos of the Evolutionary Saddle’s fit on horses backs to sell their brand. 

Unfortunately, there are many other saddle companies doing the same thing of misleading their customers.  

Timberline Saddles are back in business it would appear!  The original owner sold the business and there is another person like myself making sure that the flexible panel saddle continues to evolve and improve!

Do your homework

Ask questions of the company to confirm the legitimacy of the products they produce.

Ortho-Flex Flex Bar System

The New Ortho-Flex Gen II made by National Bridle. 

In 2000 Len Brown released Ortho-Flex, then Acie Johnson bought the company.  He changed the name to, The Ortho-Flex Saddle Works then moved to Arkansas. 

In 2013 Acie Johnson sold the company to Chase Dodd who moved it from Arkansas to Tennessee.  Bringing back the old name of the company “Ortho-Flex” and changed some of the terminology used to describe the panels from Mock to Systems.

In May of 2013, the Chase Dodd family sold the company to Winners Circle, owned by David Thomas.  A parent company to a multi-faceted organization that serves the equine community.

David Thomas, turned over Ortho-Flex to its subsidiary, National Bridle, managed by Bobbie Beach, located in Lewisburg, TN. 

Now the name has been changed back to Ortho-Flex. 

After great deliberation and looking at traditional marketing avenues, using existing materials from other saddle brands, they have conformed to a traditional build on one of the type of Flex Trees. 

Allowing for a fast and very profitable build in order to produce hundreds of saddles a year.  Gone are the panels that allowed for the ever changing back of a horse in motion. 

Traditional saddle fitting practices must now take place by using corrective pads and shims to address the horses shape as they change shape. 

What is next to come? 

You can bet that I’ll keep you posted. 

Speaking of which,I have had inquiries regarding special saddles pads.  Since many companies are now producing them. 

These pads have a white semi-rigid product in them that looks and performs similar to Delrin. 

The plastic material is NOT Delrin but a flexible type of plastic, like the kind you can nail through, you cannot do this with Delrin.  As told to Cathy Tauer  by Len Brown, developer of one of these types of pads called the corrector and then told to me. 

There is another pad, which I prefer, made by the CSI pad company that contains the Flex-Plate.  This plate is the exact design as the System V panel. 

How do these pads perform?

All of these saddle pads perform similar to an independent panel, free of the saddletree and work in conjunction with your current rigid tree saddle to aid in its performance and fit. 

The caveat is, you MUST already have a saddle that fits your horse fairly well, otherwise it will not perform as well as it should and could.

These pads, may require shims to achieve an acceptable fit and without question will help an ill-fitting saddle. 

These pads do have a place within the saddling industry.  Especially for those who have spent thousands on a custom tree saddle made for their horse. Only to find that the saddle they spent all that money on really does not fit.

As with any expensive pad, you must have the option to return it for a refund, if within the time frame offered, in a clean condition, if the product does not meet with the manufactures claims.

A new twist on panels: 

“The Living Bar Saddle”.  Uses a rigid tree, a carbon fiber shell over Styrofoam, with panels filled with carbon fiber tubes.  Some interesting points,  removable fenders and adjustable seat size. 

Make no mistake, this is a PANEL SADDLE. 

Some final words

Always get a trial period to test ride a saddle before getting trapped into product that will not serve the purpose you intended. 

If you cannot get this service, then you do not need the product. 

Remember it is YOUR money and the manufacturers’ claims to performance.

I do hope that this has helped you understand how the flexible panel saddle has evolved over the last almost 40 years.   

THE NEXT STEP

System IX

In 2005 after 35 years of combined experience in repairing all of the earlier systems of saddles. Eldorado Saddle and Tack along with Hill View Farms came up with a better panel design.

Added to the rear mounts are stainless steel slides, making the panels virtually maintenance free. Which is added to the already proven System VII panel.

However, the rivets are of copper for better strength and performance than the aluminum used in the System V and VII, and the mounts are of steel.

So radical was the improvement in 2005 on performance of the preexisting System VII, that the 7E easy slide, as it was referred to during the experimental year of testing.

It needed to be in a category by itself, thus the System IX was born.  Eldorado Saddle and Tack calls this line by a variety of names, Amera-Flex, Ameri-flex, 7E, Easy Slide and Eldorado saddles

THE NEXT EVOLUTION

System X.

During the year 2007, when the Delrin panels alone were maximizing performance in earlier systems.  Several small but significant innovations made big changes in the overall panel performance, durability and fit.

Based on the System VII design and the slide plate of the System IX, the System X has taken the features of these making this the best design yet.

However this system must have a saddle tree that is equal in design function for the panels to perform exquisitely.

The first of several changes to the panels are the rivets. 

Gone are the copper and aluminum that were once used in the layering assembly of the panels. 

Instead, there are stainless steel rivets that eliminate the work-hardening seen with earlier systems.  This fatigue resulted in pressure points on the horse.

Another improvement, the new pivot mechanism, eliminating premature ware.  With the advancements in machining Evolutionary Saddles has achieved a true ball-in-socket action.

By using different radii on the insert and the washer, this ball-in-socket joint performs with pure fluidity.  Providing maximum panel movement with closer contact. 

The clicking and popping noise once heard during the break in period of earlier systems has been virtually eliminated in this newest System X.

The Foam Backer Layer

Another hindrance in panel flexibility has been the backer and foam layer of padding used on the underside of all earlier systems. 

This padding is what cushions the semi-rigid Delrin material and the mechanical hardware used in the assembly process. Preventing direct contact with the horses back as well as eliminating the pressure ridges that occurred when inferior materials or assembly is used. 

This improved backing is fingered to match the finger cuts in the Delrin panel itself.

Having this padding match the fingers allows for the little subtleties on a horse’s or mule’s shoulder, back and wither conformation.  Especially if he has an unusual or highly pronounced scapula.

On earlier systems the panels tended to fall into the dip or hollow behind the shoulder.  This creates excessive pressure from the overall rigidness of the front of the panel, especially in the western saddles.

These small differences have made such a dramatic an improvement in the overall function of the panels.  Eliminating the dreaded breakdown of the attachment points of panel to tree which in time could possibly create uneven pressure.

Take it to the Horse

With the time, dedication and field testing starting in 1986 Evolutionary Saddles is proud to introduce this new system.

The System X is not likely to be knocked off, as the technical inputs are high and the return on investment is low.

The System X delivers a performance difference, as if you had been playing the piano with mittens and then graduated to gloves.

Where is the Flexible Panel Saddle Today?

MODIFIED EXTRAS & VARIATIONS THAT IS WHAT SYSTEMS VI THRU VIII HAVE BEEN.

System VI or Mock 6, and the later System VIII or Mock 8 by the Ortho-flex Saddle Works Company.

This system took the rivets out of the fingers of the Original Ortho-Flex System III.  Then replaced this design with a flower petal pattern in both the front and sometimes rear of the panel, resembling a 7-leaf clover.

This pattern was first conceived in the Free and Easy saddle and then copied by the Ortho-Flex Saddle Works Company.  Then bought the original Ortho-Flex Saddle Co. and the rights to use the “Ortho-Flex” ® trademark name. 

Len brown did not stop making saddles because he did not believe in the system, he simply lost his company due to poor management.

This design is also added to the rear of the panel, and offered on select saddle models as an upgraded feature.  This design can be used alone in a single layer Delrin or is used conjunction with a multi-layer panel. 

Regardless how many names of “systems” come from this single design is it all the same concept, just sliced up to make it appear as if there is more.

THE ULTIMATE

System V American Saddles-Grb (Patent in Germany only 3/9/2001-Europe # EP1292316A2)

Represents another step forward in flexible panel construction. This new construction that improves upon principles seen in its predecessors.  It offers solutions to problems occasionally associated with other systems.

Due to the uniqueness of this system and its high performance, it is currently patented, and copies no other.

Construction was changed in the front of the front of the panel.

The front of the panel is made of three layers, with 15 separate fingers, with no rivets holding them together.

In the first layer, which is mounted 5″ from the front edge of the panel, providing an even softer fit in the shoulder.  This allows complete freedom in the shoulder’s rotation.

This construction extends to the area of the withers so even extremely high and wide withers are afforded complete freedom.

This is covered by the second layer with six fingers, overlapping the first, enabling an automatic and equal distribution of weight along the entire length of the panel.  Including the middle section, preventing the so-called “bridge-fit”.

After that comes a third layer with no fingers. When put together every layer is smaller than the layer before, which is part of the progressive loading from the mount to the panel.

Construction was also changed in the rear.

This design has also three multi-layer construction.  The second layer resembles that of two fingers flowing towards the center of the panel.  This design ensures optimal weight distribution, into and including the middle of the panel.

This special design, using various sizes and thickness of Delrin, has been computer-calculated and curved.  Insuring that this system gives optimal distribution of weight along the entire length of the panel. 

Now even when your horse is in motion, bending and flexing, regardless of your horse’s shoulder width, height, holes and dips behind the shoulder and back. 

You and your horse will be able to move in supreme comfort and freedom. 

The mounts and hardware used are of steel.  The rivets used in the layering of the Delrin sheets are of aluminum. They call their saddle line American-Flex.

THE TECHNOLOGY CONTINUES

System VII (based on System V)

American Saddles continued their quest for perfection. Research tests made possible an addition, of more cuts, feathering in the top area along the spinal processes of the withers, with a more rounded front.

This made it more comfortable for those horses who have extremely high razor withers, and also for horses who have broad and wide withers.

It will even fit those horses with “heart-shaped” backs where you can roll a marble down their spine.

Overwhelming success during 2002 confirmed what computer scans recommended. Horses and riders are thrilled with the panel’s success.

COMBINATIONS

System VIII or Mock 8 

Saddle Works Ortho-Flex combined the single layer System I with the finger cuts of the System III, by cutting short the front of the panel.  All done in order to address the issue of excessive pressure at the mounting points in the saddle. 

This really does not qualify as new system but modifies preexisting ones. 

However, they are calling this combination System VIII, which still requires great care in fitting.  Due to the horses shape, the correct saddle tree is necessary in order to achieve an acceptable fit.

A New Development – The System IX & The System X

The System III and System IV were good evolutions that needed to be taken a step further.  Their contribution to later Systems was invaluable. 

THE EXTRA: System III

In the quest for further progress, the Original Ortho-Flex developed this panel. It was designed to address fitting the most difficult horses to saddle; those with very pronounced shoulders, or mutton-withered and broad.

That difficult conformation is often exaggerated by a short back or croup-high conformation. It’s also seen some in warm-bloods. (For history, the “original” System III is patented as part of system or mock II (2/18/1994 -USA), and was based on three mountings, on either side of the saddle bars, allowing the panel to slide.

Ortho-Flex Saddle Company never built this system because it did not work. So there are no laws or patents to protect the current System III.

This system was then modified based on the System II with a refinement in the front part of the panel; it looks like a giant hand with five fingers. These fingers allow the panel to conform itself even more closely to the shape and motion of the shoulder, thus offering more freedom of movement.

Two results of this new construction is that it was only offered as an expensive option on some saddle models, and the use of rivets to stabilize the five fingers resulted in excessive stress which causes the fingers to either crack or break.

THE ADJUSTABLE: System IV

Pro-adjustable, tied into the extra system III patent, could be regarded as a high-tech breakthrough in flexible panel systems. The height of the panel mounting points can be adjusted quickly and easily with the use of an Allen wrench. 

Allowing the user to optimally balance the saddle and the rider, even on a horse with truly unusual conformational challenges.

THE LICENSE

This license from the Original Ortho-Flex Saddle Co. was sold to “Rocking R” who then changed their name to Timberline.  Then was sold to K-B Saddle Shop – who kept the name.

SK Saddle, Watson Brothers Saddles (former Rocking R) for a time sold out to Ozark Mountain Saddles.  Since then have terminated relations with Richard Watson and the Saddle Ranch.

This system is a hybrid of Ortho-Flex Systems I and II. Those saddle companies do not utilize the System II mounting method. But rather offer the track system at the back of the panel.

Like System I, they are also built on a single layer of Delrin, but thicker (1.25 vs the .093) allowing for rider support.

The saddletree selection is crucial to the panel and tree configuration.  As is the choice of thicker Delrin enables this system to perform nicely.

The panels are also capable of some flexing in the middle, although not to the degree that the higher systems offer.

This saddle construction, like the System I, is more like a saddle with a flexible panel, than a real system.

Due to the adjustable rigging, the saddle can be positioned to compensate for this difference most of the time.  This allows it to be fitted relatively well to a wide range of back types.

THE VARIATIONS

The Ultra Flex, Oakfield, Ultra-Flex Vario, Ultra-Flex Adjuster, Reactor Panel Saddle and lastly the Free & Easy Saddles all have a multi-layered Delrin panel. 

Some have removable and or adjustable mounting spots to adjust for the limitations.  Both in the panel and the tree design when fitting the saddle to the horse’s shoulder and back.

Great skill and knowledge is required to achieve a good fit, because these panels are not truly self-adjusting.

The Story Continues – System VII thru System VII

The System II or Mock II Patent (8/15/1991-USA) began in 1990.

The Original Ortho-Flex developed a breakthrough in the existing technology. 

The System II offers a new mounting system for the panels, allowing the panels to conform to all three dimensions of motion dynamics.  Providing an automatic fit, not only in the shoulder rotation, but also along the back.

The rear of the panels are mounted in a track that enables the entire panel to conform to a radical range of back contours.

This addition of the sliding mount at the rear, the panels actually push down and away from the center of the tree.  With the right force that enables the entire panel to conform to a radical range of backs. 

Most importantly, they allow the panels to conform to the horse while the horse is motion, independent of the tree.

The System II, the panels are away from the tree about 1/8″ to 3/8″ on steel rocker spacer mountings.

The Layering

The construction of these panels is 3 layers of Delrin at the mounting.  Each one is successively smaller, creating what is termed as “progressive loading”.

This makes pressure points virtually impossible directly under these rocker spacers.  Mounting the front mounts 4.5 inches back from the front edge of the panel allows for scapula rotation.

In addition to its other advantages, System II can rise or sink with the back.  Then became the flagship system for the Original Ortho-Flex Saddle Co.

After the Buyout

Following the buyout of the Original Ortho-Flex Saddle Company by Saddle Works Saddle Company, they made a change to the mounting.  

The panels are now mounted only 2.25 inches in from the front of edge of the panel.  This stiffens up the panels in the shoulder area inhibiting the shoulder’s range of motion.

Next: The Extra, Adjustable and the License – System III and System IV

Delrin^® Panels are available for saddle makers worldwide to use on their saddles! Developed by the NASA space program, Delrin ^®  is used throughout all aviation aircraft and in the medical field.

The Original Ortho-Flex ^® Saddle Company developed the panels using the Delrin sheets, which were the heart and soul of Ortho-Flex.

Don’t Be Misled

There are many companies that use the word “flex” in their marketing to sell their saddles. 

Make sure you are getting the Delrin^® panel and not some facsimile of “flex”, “panel”, rubber or rawhide.  Some even have wood or plastic bars that are hinged on the fork and cantle.

A horse’s shoulders and back move with every step.  The “flex” needs to move as quickly and as freely in all directions, while distributing the rider’s weight evenly.

Delrin^® material is such a product. It will not fatigue, misshape or wear out easily, and will last over years of riding. 

One critical point to remember when buying a saddle is that the basic saddletree itself must be straight, not handmade.  The CNC machines that make these saddletrees are key in the function of your saddle.

I’ve put together a retrospective look at the different types of flexible panels as they evolved starting in 1982 and those offered to date.  I wanted to better illustrate the progress in technology represented by various saddle makers.

We begin with the foundation technology, from the Original Ortho-Flex 1 System.  This original system  subsequently led to Systems II, III, IV, V, VI VII, VIII, IX, and X with the variations and extras.

What is Delrin^® 

Early in 1950 research director and chemists Frank C McGrew developed a tough and heat resistant material he called “synthetic stone.” 

Delrin ^® (Polyoxymethylene) is an acetal homopolymer resin that is a durable lightweight crystalline plastic.

During the years of development, which involved a patent dispute, DuPont patented Delrin® in 1956. 

It has an excellent balance of desirable properties that bridge the gap between metals and ordinary plastics.

Delrin^® has memory, that allows it to return to its natural shape. This is imperative for the horse so that the panel is never stuck in any one flex. 

With a unique combination of strength, stiffness, tensile strength, and hardness.  Coupled with the dimensional stability, fatigue resistance, solvent and fuel resistance.  Not to mention the abrasion resistance, low wear, low friction, with high fatigue endurance, corrosion resistance and mechanical resilience.

These outstanding characteristics of Delrin^® make it popular for its versatility.

With a broad use in industry applications, such as automotive, aerospace, electrical and medical applications. 

The First Delrin Saddle Panel

The System I or Mock I patent (6/26/1986-USA)

The original system used when the Brown Performance Saddle Company started in 1982.

Len Brown then incorporated his business and the Ortho-Flex Saddle Co. came into existence in 1986. This is the first and oldest system developed by the Original Ortho-Flex, and marks the beginning of the Ortho-Flex story.

This relatively simple system, with one layer of Delrin in the panel. System I is capable of allowing enough room for shoulder rotation and fits a wide range of back types.

However, it is not fully capable of following the full range of motion along the back.  It cannot sink or rise in the middle, for example, as the panels are not fully independent of the saddletree.

It is therefore necessary with System I to pay attention to the type of tree relative to the type of back, and is not as “user-friendly” as the systems to follow.

The Ortho-flex saddle with System I panels is still regarded as a flexible panel saddle.

As is the flexible panel system in later evolutions that is fully independent of the saddletree.

Made of a single .093 inch of Delrin, the panels were attached to the tree about 6″ inwards from the ends of the bars.  On top of that the panels were 1 ½” longer than the successor, System II.

Creating longer skirts, not ideal for short backed or deep backed horses.

The panels were mounted with a wood screw and washer into the tree. The system had a few advantages, being less expensive to build, and a little easier to mount the panels.  

This system was eventually replaced by System II.  Since it did not allow the panels to flex downward in the middle with the horse’s back. 

Requiring the panel stiffness to be adjusted to compensate for the increased rider’s weight.

Tree shape was also critical for the system to function so custom fitting through tree changes was often necessary.

The System I was a vast improvement over the traditional saddle in weight-bearing area.  Although it required a tree shape not adaptable to all types of riding.

In the next installment we’ll go over the System II – “The Successor – A New Mounting System”

The Liberty a model of Evolutionary Saddle is constructed very similarly to your traditional saddles, except for the panels.  

In many ways the Evolutionary saddle is easier to construct than all of your traditional saddles, which is what makes it so customizable for the rider.  The panels will fit the horse, so much of the construction is centered around rider comfort.

For instance this saddle has a soft seat with a narrow twist and waist then gradual rise. This is a popular style seat for many women that trail ride. The seat is designed and sculpted to provide a balanced comfortable ride for hours in the saddle.

This saddle was made with a pencil roll or what has been called in the past a regular roll. This style makes the cantle taller and brings with it a secure feeling for the rider. This is a full soft seat that actually shrinks a seat size by about a 1/2″. I have a similar seat style that doesn’t rob the rider of that room in the rear but will still provide a comfortable ride, I call it the Hybrid Soft Seat.

Here is a glimpse into how The Liberty, an Evolutionary Saddle, is constructed!