How to Make Your Own Chainsaw Chaps

Take the measurements on your body that will be required for the chaps, including the distance from the top of the thigh to the bottom of the ankle, the circumference of the front half of the thigh from side to side, the circumference of the front half of the knee and the circumference of the front half of the ankle. Measure the distance from the the top of the the thigh to the top of the knee and the bottom of the knee to the bottom of the ankle. Note all measurements on paper.

Make an outline of the chap on a double thickness of leather for one leg, using the measurements from Step 1 and accounting for any variation in the individual leg. Cut out the first chap, cutting through both thicknesses of leather using a utility knife. Repeat for the other leg.

Make an outline on the metal sheeting of the thigh and the lower leg. Use the dimensions for the thigh to knee and knee to ankle as the lengths, and remove 2 inches from the measurements for the circumferences. Cut out the metal sheets with metal snips, and place the pieces in their appropriate places between the layers of leather. Bend each metal plate between the leather layers to fit the legs comfortably.

Sew each metal plate in place by sewing completely around the circumference of the plate through both layers of leather. Position the small leather belts between the layers at the knee and the ankle openings so that the buckles are in back for easy tightening. Pin the belts in place. Position both chaps the necessary distance apart on the waist-length belt, with the belt running between the two layers of leather at the very top. Pin the waist belt in place.

Sew completely around the edge of the chaps, sewing the belts to the chaps with a few extra lines of stitching, and then trim off any uneven and extra leather fabric resulting from the bent metal.