Category: System X Panels

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My Hard to Fit Horse

My Journey Starts

I had a hard to fit horse, I have probably always had hard to fit horses, still do! I just know more now than I did then. That is the beauty of the equine industry, no matter which part you participate in. There is always something knew to learn.

Dixie is where it all began, a quarter horse mare, with asymmetrical shoulders. I didn’t have a saddle that fit her, all of them pinched and poked her in the shoulders! The hunt began for a saddle that would help, she already had white hairs and they were only going to get worse if I didn’t do something about it.

Is There a Better Fitting Saddle?

I had run across this saddle in my window shopping at the time. After reading the Hillview Farms website front to back I decided that was the saddle I was going to spend whatever it took to put it on my horse. I studied that website, discovered that it came from a long and rich history of trial and error. I am grateful for this, as I felt that it gave us all this superior panel that does what those previous generations of panels were only starting to do. Which was redistribute the weight of the rider over a wider area and flex with the movements of the horse.

I read that 1995 website from cover to cover. There was a books worth of information out there and I devoured it all. I watched that website and planned my custom saddle, since at the time I couldn’t afford one. After waiting several years I saved the money, so I was going to make the trip to buy or order a saddle. Yeah, I bought a saddle off the rack because as soon as I sat in it, it was coming home with me. It is the saddle that I ride in to this day.

I bought the saddle in February. I had a few months to wait to have my first rides in it. Offering to put first rides on all my friends horses just to get a chance to try the saddle on all the different shapes. To see if it lived up to what the website had told me. It certainly did exactly what it said it would.

A Good Fit for Dixie

As mentioned earlier Dixie had asymmetrical shoulders, meaning that one was slightly smaller than the other. Part of this was her compensating for the arthritis that precipitated her retirement, but also because all the other saddles that were used on her put a lot of pressure on that shoulder, pinching her.

As we used the saddle more, her topline evened out now that she had room to move under the saddle. The saddle moving with her. I remember those first rides when I could feel the panels move under me. Dixie also like the saddle, you could tell by the way she moved and behaved.

It Fit All of the Other Horses I rode

I have ridden many miles on a wide variety of horses that have been shaped so differently that for a while I was continually amazed at the results.

So I took the saddle on a real test. The Silver Spur Ranch World Famous Horse Drive in Idaho. My riding partner also took her Evolutionary saddle to ride in on the horse drive too. We rode five days, 20 miles a day over mountainous terrain. We watched the wranglers have to make all kinds of pad variations. Trying to prevent their horses from getting sore, especially over the loin.

Each morning we’d see them check their horses’ backs. Eventually they stopped checking the two horses that we were riding as our saddles weren’t soring their horses. So not only were we comfortable during all those miles, so were the horses we were assigned for the week!

Thank you Dixie!

If it weren’t for her, that started me on the journey to find a better saddle for her, I wouldn’t have found the Evolutionary Saddle. I wouldn’t have wanted to learn how to build them and wouldn’t have ever had the opportunity that presented itself in 2020.

Dixie passed in the fall of 2023, but I continue to test my saddle on any horse or pony that I get the chance to ride and I ride my new mare Gracie in it. Continuing to learn, from the horses, ponies, mules and donkeys that I come into contact with. Each one providing an education that you just can’t get anywhere else.

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Flex Panel Saddles: Addressing the Misconceptions

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.

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The System X How does it fit?

The System X construction – Why and How does it work?

The appropriate System X panels for each size of tree are built on to fit your horse and distribute the rider’s weight for a lifetime.

The System X panels are made out of a DuPont material called Delrin.  It is a glass product that the inventor liked to call synthetic stone.  The panels are not  plastic or rubber put on inferior trees that make up the familiar 5-7 year replacement saddle industry. 

The Evolutionary Saddle is built using only quality materials sourced as much as I can here in the USA.

Starting with the solid ponderosa pine saddle tree encased in Kevlar® then finished with DURAhide!  Made by The Precision Saddle Tree Company in Yoakum, Texas.

The tree comes with a limited, conditional ten year warranty. Limited and conditional to the normal use of the tree.

As you can see there is the bottom layer with all the fingers cut in it. Making it the base closest to the horse. 

The next layer also has fingers in it in the front with a long tail that leads to the rear second layer that has a couple of fingers in it as well. 

The final layer that is closest to the saddle tree is the smallest and is where the mount from the saddle tree meets the panel and its weight distributing layers. 

This type of layering is progressive and provides the maximum weight redistribution across the entire panel from front to back. 

The System X Panels – All About the Horse

This is a picture showing the panel construction. You can see that it has a multi-layered, balanced structure. This is very important, because only in this way is it possible to distribute the load over the entire surface.

A single-layer panel, as found under other flexible panel saddles, is flexible only in the ends. It looks nice, but it doesn’t distribute the rider’s weight. You ride such saddles – like any other saddle – on the bars of the saddle tree.

If connected with joints, a single-layered panel could even have disastrous effects. The joints could push through and cause uneven loads in certain places. With our saddles, the tree and supporting surface are independent.

One System Working Together

The panel and tree form one unit, yet they are isolated from each other. Meaning the supporting surface on the horse can assume a shape quite different from the shape of the tree.

When placed on the horse’s back then carrying the rider, the panels follow the laws of mechanics and are forced to conform to the horse’s contour.

This will result in flush contact over the entire surface with even pressure distribution.

The front part of the panel is built with slats. This permits an extra soft shoulder rotation.

Even during movement the panels adapt to the constantly changing shape of the horse’s back.

The slats extend as far as the withers area, so horses with extremely wide withers never feel too much pressure on this area.

The second layer of the panel overlaps with the slats from the first layer. Transferring the forces to the subsequent layers.  Also a simultaneous distribution to the center of the panel through the fingers that extend there.

The remaining course, the panel construction guarantees an optimal distribution over the entire surface. Weight distribution takes place in several “stages.”

The special shape of each layer guarantees an optimal weight distribution over the entire panel – even in the middle.

The Saddle Tree – All About the Rider

Having a great panel and mounting system does not assure that a saddle will perform correctly on your horse or mule.

A traditional rigid saddle tree is designed to offer the rider support. At the same time, it attempts to distribute the riders weight evenly over the horses back.

However, in our case, the Evolutionary Saddles’ tree is designed to offer the rider support.  Then are designed to carry the System X panels which provide the even weight distribution over a moving horse’s back.

Having a saddle tree be too thick, too straight or too narrow – not to mention crooked –would not allow the System X to perform properly.

Which is why the saddle’s bars are designed to carry the panels and the panels are designed to fit the horse.

After a very diligent search for repeatable perfection brings me to The Precision Saddle Tree Company.

Using modern technology not previously employed by the saddle tree industry, Precision Saddle Tree Manufacturing delivers quality and uniform trees.

They use only the best materials. Precisely engineered designs and hands-on production ensure quality saddle trees that last a lifetime.

About The Precision in the Precision Saddle Tree. 

Precision Saddle Tree Company uses three-dimensional scanners combined with CAD software to engineer the pieces that are cut on their CNC Machines.

Their equipment allows parts to be produced that are precisely the same each and every time. The right bar is a mirror image of the left bar.

The right side of the swell is identical to the left side. This unmatched precision provides greater strength and the highest level of consistency in the industry.

Saddle trees are made with Ponderosa Pine with a ground seat, then two different tree coverings are applied.

The first covering consists of hand-laid Kevlar® that is wrapped around the horn, swell, bars and cantle and with a clear coat resin.

The second covering is made using a product called DURAhide™, which is sprayed over the Kevlar®.

What is Kevlar®?

Is a heat-resistant para-aramid synthetic fiber with a molecular structure of many inter-chain bonds that make Kevlar® incredibly strong. 

Best known for its use in ballistic body armor, Kevlar® also has many other applications because of its high tensile strength-to-weight ratio.

What is DURAhide™?

DURAhide™ is a polyurea elastomer that is specifically formulated as a high performance coating designed to prevent damage from moisture, corrosion, abrasion, weather and wear. This material is not only an effective sealer, but adds strength to your tree. DURAhide™ carries a tensile strength of 2300-2500 lbs psi @ 75F. DURAhide™) withstands temperatures from minus 50 to plus 350 degrees Fahrenheit.

I inventory a supply of trees for quicker build times!

The Precision Saddle Tree Company is a stable company able to offer the best saddle tree in today’s industry that carries a lifetime warranty.

Next – Why My Saddle with The System X?

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Where is the Flexible Panel Saddle Today?

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.   

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The Next Evolution – System IX and The System X

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?

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Systems VI thru VIII

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

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The System III and System IV

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

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System II – The Next Mounting System

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

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Delrin Panels Available Worldwide

System I

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”

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Why My Saddle with The System X?

Did you know that 80-90% of horses experience back problems?

Many riders assume these issues come from poor riding posture, but the biggest culprit is often the saddle itself—an ill-fitting saddle can cause discomfort, pressure points, and long-term physical damage to both horse and rider.

Unfortunately, many horses suffer in silence. As natural prey animals, they are conditioned to tolerate discomfort. But just because they endure it doesn’t mean they should have to.

Recognizing Saddle Pressure: It Starts Before You See the Signs

Many riders believe saddle pressure issues show up as white hairs, swelling, edema, or dry spots—but by the time these visible signs appear, the damage is already well underway.

Instead, the earliest indicators of saddle discomfort are found in your horse’s behavior. The key to catching problems before they become serious is palpation—physically checking your horse’s back for tenderness before and after riding.

This hands-on method is:
✅ More accurate than computer-generated saddle fit measurements.
✅ Immediate—you can check your horse right now, no fancy tools required.
✅ Cost-effective—it doesn’t require expensive diagnostic equipment.

To get the best results, palpate your horse:
📌 Before riding – Establish a baseline.
📌 Immediately after riding – Look for sensitivity or soreness.
📌 48 hours later – Just like humans feel soreness two days after a tough workout, horses experience delayed-onset muscle pain too.

👉 Want to see palpation in action? Check out my YouTube Playlist “Palpating Your Horse” for a step-by-step guide.

The Truth About Saddle Pads & Shims

Many riders turn to pads and shims to “fix” saddle pressure issues. While these solutions can provide short-term relief, they don’t eliminate the underlying problem—an ill-fitting saddle.

Instead of spending hundreds of dollars on temporary fixes, a System X saddle helps distribute pressure evenly across your horse’s back, reducing the need for additional padding.

How Does a Horse’s Back Move?

To understand why conventional saddles create pressure points, let’s look at how a horse moves:

🐎 Standing still: A horse’s back has a slight arch. A rigid saddle can “bridge,” leaving a gap in the center and causing pressure at the front and back.
🐎 Turning: One side of the horse’s body shortens while the other stretches. A conventional saddle can’t adapt, increasing pressure on one side.
🐎 Lowered head / downhill movement: The spine flattens, shifting pressure to the front of a rigid saddle.

The result? A conventional saddle will always create pressure points—it’s just a matter of when and where.

Why System X Saddles Make a Difference

System X technology allows the saddle to move and flex with the horse’s back, rather than working against it. Unlike rigid saddles that lock the horse into a fixed shape, System X panels adjust dynamically to distribute weight evenly.

To illustrate the difference, think about a metal-frame hiking backpack:

🎒 If it’s too small or too big, it rubs, creates pressure points, and causes discomfort—even injury.
🎒 Now imagine running, jumping, and climbing hills with it on—that’s what a horse experiences with an ill-fitting saddle.

You can test your own saddle fit by sliding your hand under it (without extra pads) and checking the front, center, and rear:
👉 Without a rider, do you feel gaps or pressure points?
👉 With a rider, do you feel pinching?

What your fingers feel in that moment is what your horse feels for the entire ride.

One-Size-Fits-All? Not for Saddles.

Horses come in an endless variety of shapes and sizes—yet most conventional saddles rely on 8-15 standard tree patterns. Look at any pasture, even within a single breed, and you’ll see massive variations in:
✅ Shoulder width
✅ Wither height
✅ Back length and shape
✅ Croup angle

Can a factory-made saddle truly accommodate all of this?

A System X saddle is designed to adapt to your horse’s changing shape, giving them the freedom of movement they need—without pressure points.

The Bottom Line: Change the Saddle, Not the Horse.

Horses are incredible athletes, constantly growing and changing. A saddle should move with them, not force them into a rigid shape.

If your horse has been showing signs of discomfort, it might be time to consider a better-fitting solution.

Want to learn more? Check out Are there Options? to explore the next step in saddle fit solutions.

Photo courtesy of Carlee Strack

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Are there Options?

I have been there, wondering what are the options and how much am I going to have to spend on a saddle?  How long will it fit before I am on the search again?  What if it doesn’t fit me too?

How can the traditional saddling industry, cover all the variations of shape of our horses? Not to mention riders?! Truth is, they can’t.

At best, they offer only a handful of saddle tree patterns to choose from, then you and your horse must conform to those few choices. That is like saying that you must only select a pair of pants to wear from only 4 sizes.

Now that we have established the fundamental variation in horse backs, we still have the problem of how the shape of a horse changes with movement.

Finally, the same horse is continuously changing over the course of its life! As the result of growth, aging, training, conditioning, feeding, etc. its contours are constantly evolving.

This last point alone means you need to alter a production saddle or acquire a new saddle every six to twelve times over the course of a horse’s life. An investment for sure.

If all of this wasn’t bad enough, another structural problem now arises, the pressure load on the horse’s body resulting from the rider’s weight.

What does all that do to the horse?

As we know, excessive pressure damages the hair, skin and all of the tissues underneath.  That is where the dry spots, white hairs and sometimes even open sores can occur, all from pressure. 

Let’s take a look for example at an English saddle.  An average English saddle has a supporting surface on the horse’s body of approximately 27 square inches. Then, we put another 165 lbs onto the saddle – the rider.

This gives us a load of 39 oz. per square inch. Acceleration, gravitation, etc. may at least double this value during movement, producing a load of 78 oz. per square inch.

Let’s repeat this calculation with a western saddle. An average western saddle has a supporting surface of 96 sq in. 

Let’s take our 165 lb rider again, giving us a load of 28 oz. per square inch or 55 oz. per square inch during movement.

These values are valid for contact over 100% of the supporting area. As we know however, the horse alters its shape during movement, making this 100% completely impossible to attain.

Even if you add at least 1/4 to the load, your calculations will still be very much skewed in favor of the saddle. Now, think back to that 24 oz limit once again.

So for review, any activity that involves concussion (jumping, posting, etc.,) will effectively double or even triple the rider’s weight.

What is that doing to our pound per square inch?

Are we causing damage?

The only way to know is by palpation. You can see a video how to palpate your horse!

What are the options?

Is a flexible saddle tree an option?

This was out of the question, since it would not solve the basic problems of fitting the horse AND providing a stable seat for the rider.

It should not be like sitting on a sponge. But that would be the logical consequence if the saddle tree were to actually follow the horse’s movement.

Another effect would be a sagging of the tree, which would in turn concentrate the weight on certain points especially the spine The final point against the flexible tree was that it would not have a large enough supporting surface to meet our – or rather the horse’s – needs.

An adjustable saddle (bars & gullet)? Well yes, not such a bad idea but here again it would still be subject to the basic constraints of fitting it to the horse.

Also, any adjustment reaches a limit at some point, not to mention that in this case the “normal rider” is always dependent on assistance from others (saddle dealers). In addition, we did not want something that is calibrated but something that changes continuously.

First, because there are almost infinite variations among horses, but also because these variations are gradual and not divided into standardized sizes.

These comments also apply of course to these interesting variations of “saddle systems” that work with individually added padding.

The Option of Custom made saddles?

On the basis of all these considerations, we rejected the idea of custom made saddles from the beginning. Even a custom-made saddle can only, in the best-case scenario, fit the horse 100% in a standing position, and then only with respect to the horse’s present state.

A treeless saddle? 

Also not such a great idea. With this, there is no need to take the traditional fit parameters into account. But there remains the problem of uneven, selective weight distribution.

And the added problem of the pressure load on the spiny processes, because a treeless “saddle” cannot keep this area clear.

Which is what makes the treeless saddle not the ideal to fit both horse and rider.  Although a better option than saddle that doesn’t fit at all on a horse where a treeless at least allows them to move in some comfort. 

Independence between fit for rider and fit for the horse!

A saddle in which the supporting surface is independent of the saddle tree, conforms to the widest variety of horses, then able to adapt to the horse during movement. Additionally is large enough to distribute the weight over an area that is more than sufficient.

Thus the purpose of a saddle. To offer the rider support while distributing the rider’s weight over a large surface area.

This was the beginning of the various systems that revolutionized the panel saddle.

With the System X there is a strong, inflexible tree as a “chassis” to give the rider the desired stability. Mounts are attached to this tree to connect it to the panels.

These mounts are shaped to allow the panel to move in all three dimensions (up, down, side-to-side)– independently of the tree! In order to guarantee that the weight is distributed over the whole panel, we have chosen a material that is very smooth and flexible – Delrin.

At the same time, it is strong enough to distribute the force over the entire surface. This was very important, because only in this way will it work as a whole.

Of course, there are many saddles “out there” that resemble these panels, where the panels give way in the front and behind, but they are not really able to actually distribute the weight.

All other saddles – whether flexible or traditional – have one thing in common: you ride these saddles on the bars of the saddle tree, which is the source of the problems.

Finally, let us repeat the calculations we have just done of the load per square centimeter [inch] on the horse’s back.

Our saddles have an average supporting area of 324 sq. in. This means that the calculations result in values of 20-40 oz. per sq. in.

And since our panels join in the movement, we don’t need to make any reductions in the supporting surface. We are obviously far below the 105-gram limit.

As you can see it is actually quite easy to build a saddle that is truly horse friendly.

Photo courtesy of Carlee Strack

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How to Saddle with a Flexible Panel Saddle

I am contacted almost everyday from folks that have picked up a pre-owned flexible panel saddle and have trouble their first time out with the saddle.

Sometimes this has to do with fit or functionality of the panels, but most of the time it has to do with placement of the saddle on the horse’s back.  

Because so many people have requested help with fitting a flexible panel saddle, I decided to dedicate an article to the subject. 

Sox vs a Pad or Rug

Rule number one, never use a pad or rug that is over ½ inch thick under any flexible panel saddle.  A thicker pad will prevent the panels from functioning.

Rule number two, when using anything other than Sox or Booties on a panel saddle you must tent the entire spine by pulling the pad or rug up into the spine of the saddle, from the front to the rear.

For optimal performance Sox or Booties are the best choice. Since Sox and Booties attach to each panel individually there is never any pad to mess with.  

You just saddle up. This will make you the envy of your riding friends as you saddle up in half the time. 

Saddle Placement

Saddle placement is where the first mistakes are made.  When you look at a panel saddle you need to ignore the panels.  

With a rigid tree saddle you place the front of the saddle bar 2-3 fingers behind the scapula. Think of the point at the swell base on a panel saddle as the front of the bar of a rigid tree saddle.  It is from there that you apply that 2-3 finger measurement. 

This will cause the panel to overlap the scapula by up to three inches. That is OK, because fingers are cut into the front of the panel that will allow that scapula full freedom of movement.

After placing the saddle, step back and make sure the saddle is level from swell/pommel to cantle.  If it is not level, then the placement is off or you may need shims.  (There are some extreme exceptions, but those are special cases.)

Cinching or Girthing up

Once the saddle is placed in the right spot and the top is level, it’s time to check and  adjust the rigging so that the girth or cinch will fall along the heart girth area on that horse. 

When adjusting the crossfire rigging, be sure that the tension is the same on both straps that attach to the saddle. If the tension is not even in the rigging straps it will cause an unstable feeling when riding. 

Rule number three when cinching/girthing up NEVER use one that has elastic attached to the buckles. Elastic cinches/girths will cause the saddle to ride like a car without shocks because the panels provide the give that the elastic would be providing to a rigid tree saddle.

So how tight do you tighten a saddle like this? 

My best description is you tighten like you always have and then just a lil bit more. Basically, you are over tightening a little bit. Once in the saddle, reach down and feel the difference. You’ll notice that the cinch or girth is not as tight as it was, that’s the flex of the panel.

 While saddling this type of saddle is different, it really isn’t that different from what you were taught, so don’t let it overwhelm you.

As always, if you have any questions never hesitate to contact me!

Or reach out to me on Facebook or Instagram…

Photo courtesy of Carlee Strack

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Design Your Saddle

Are you looking for a saddle that fits both you and your horse perfectly? We understand that finding the right saddle can be a long and sometimes frustrating journey, filled with both disappointment and joy. You may find a saddle that fits your horse well, but after an hour of riding, you’re in so much pain that you can hardly dismount. This is a common struggle I hear about when new clients are looking for a new saddle for both their horses and themselves.  So I’d like to share my process of helping you design your saddle.

Things to Think About

What was your favorite saddle to ride in?

For the purpose of this question it doesn’t matter if it fit your horse.  What matters is whether or not it fit you and what you loved and/or hated about it.  The System X panels are designed to provide fit and comfort for the horse. So here is where I concentrate on helping the rider be as comfortable as their horse will be. 

What saddle did you hate to ride in but it fit that horse?

As people we tend to dwell on the things we didn’t like better than we can recall what we really liked about saddle. Which is why one of the first questions I ask you when helping you design your saddle is what you couldn’t stand about some of the saddles you have ridden in over the years.

What style saddle are you looking for? 

Something with a horn? No horn? An English style saddle? Flapless? Extra Blocking for security? 

Some of this is cosmetic and some is functional, while some is just personal preference.  For the different disciplines there are also requirements for the equipment used.  Dressage is a perfect example of specific requirements for the saddles used in competition. 

These are things to keep in mind, such as what will you be using the saddle for? Will it suit all those needs?

What seat and size is suitable for you?

Like clothing and shoes, saddles will vary in comfort even if they are the same seat size. The rise, waist and twist need to be considered along with the size of the seat. As these things allow a rider to sit centered and balanced.

Considering the size of seat there are thee things to consider, shape, weight and physical limitations of the rider.   Other factors include the build of the rider, their experience level when riding and the discipline that they have chosen.  These factors and others help determine for each individual rider what seat and size is best for them.  

How would you like the cantle finished?

In western saddles there are a variety of ways you can finish a cantle.  Although the most common are either a Cheyenne roll or a pencil roll.  There are some variations that are based off of those two styles, but most fall one way or the other. Some have a cantle where the seat leather just sweeps over and nestles under the seat jockey in the rear.  English and endurance saddles are often this style. 

Weight, is it a factor for you?

None of us are getting any younger, so the weight of the saddle we lift up to our horse’s backs can be a growing factor.  I know many that love their 50 lb saddles but can’t lift them anymore.  While I can’t make my saddle under 16.5lbs because of the solid wood tree and the System X panels. 

The weight of the saddle is a factor for many riders, and we’ll work with you to reduce the weight while still maintaining the quality and comfort of the saddle. Working closely with you throughout designing your saddle, ensuring that your vision comes to life in the way you imagined. We want to make sure that you’re not only happy with the saddle we build for you but also supported as you learn to use it and make all the necessary adjustments as you ride multiple horses.

The Experience

When you choose to design your forever saddle with us, it’ll be more than just the color of leather, style of saddle, and choice of tree. Discussing any physical limitations you have and any future plans you may have in your riding career. Let’s talk about your new saddle and start the process of building your custom forever saddle.

Schedule a Saddle Consultation
Plan Your Saddle
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The Liberty

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!