Table of contents
Bilski
clothing
Boots
Boot manufacturing
Boot manufacturing
Small work
In Eggenfelden in Lower Bavaria, MOTORRAD observed how a 100-piece puzzle is turned into a boot.
Holger Hertneck
12/24/2003
A look at the many individual parts (see photo above)
of a high-quality motorcycle boot illustrates the effort that goes into making it. A good 80 work steps are necessary before the individual components are turned into a shoe. At Daytona, which is managed by the brothers Helmut and Reinhard Frey, except for
the rubber soles and zippers practically all parts are made under one roof in Eggenfelden. Even the small fastening screws for the plastic protectors are self-made.
Almost 100 employees produce around 60,000 pairs of motorcycle boots per year. The best-selling model is the Road Star GTX, a robust, sporty touring boot with a Gore-Tex membrane. Over 50 percent of Daytona boots are equipped with this functional membrane. The Lower Bavarians forego the processing of artificial leather or leather substitutes in favor of the natural products calf, cow or kangaroo leather. Perhaps the most famous professional racing boots on the market, the Security Evo, which were created in collaboration with Grand Prix drivers, are made from the latter. They are distinguished by one
extremely stable aramid-carbon inner shoe that still allows full mobility thanks to a joint.
Daytona: Report on boot manufacturing
1 According to Reinhard Frey, one of the most important components of a boot is the insole. As the bottom layer, it has a so-called coverer, its
handy bottom for later processing-
processing steps as
Adhesive aid is used. There is also a steel insert and a mixed textile fabric for the front foot section. The last component
is made of plastic (polypropylene), the
is injected in a machine and the
Connects parts to one unit.
2 For every boot model and size
There is an assortment of punching dies with which all necessary leather and lining parts are punched out of large leather hides or strips of fabric on presses. In the next work step, employees deburr
special machines
the cut edges and
flatten them. This so-called sharpening enables that
Sewing leather parts together so that they overlap without doing this
thick beads arise.
3 Then
embroider semi-automatic machines
the leather parts provided for this, the company logo and other lettering. The gear lever reinforcement on the forefoot finds the right place with the help of templates. Manual work is required to glue in the plastic reinforcements for the heel area.
4 Likewise when welding the functional membrane. This process is called taping. A narrow sealing strip is applied to all seams of the multi-layer, waterproof inner lining at around 360 degrees. Finished welds are randomly checked for leaks.
5 By far the greatest number of employees are in the sewing shop
busy, where almost exclusively women with a lot of manual skills put the individual parts together. The boot leg is made
after that already out
one piece, however, it is still quite informal.
6 With plenty of pressure at around 90 degrees
He receives warmth
Heel area one
first preform. In order to
if this is retained, it must be restored immediately afterwards
be cooled down.
7 Now the insoles come into play, those on the last
to be nailed. The lasts are pretty much the boot manufacturers’ biggest secret, as their execution is responsible for the later fit of a boot.
8 When overtaking or pinching, the boot uppers are in a kind of steam chamber
heated, which makes the leather soft and elastic, and then pulled over the last. If they are waterproof leather boots with a membrane, glue is used, otherwise
nailed. Machines that appear futuristic press the tip of the foot,
Joint and heels-
area almost to the
Last around, making the boot shape clear for the first time. The next work steps are roughening and planning the sole area as well as marking the later sole edge position using a template and pen. The bottom area of waterproof boots is given a
Another layer of foamed plastic for sealing. Now all will
Boots on the edge of the sole
roughened and freed of dust and chips using compressed air.
The delivered rubber soles are also roughened
and for gluing
made ready.
9 After a preparatory adhesive,
which penetrates deep into the material, nimble hands brush the two-component main adhesive onto the adhesive surfaces. This glue must act for at least 30 minutes before the rubber sole and boot shaft are joined together.
10 For this purpose, the sole and upper are first
heated to 70 degrees to
the glue again
to activate, and then merged by hand.
A press that presses both parts together at eight bars strengthens the connection.
11 Now the lasts can be removed from the practically finished boots, which requires a bit of strength and is appropriately referred to as the molding. Then employees grind off excess adhesive residue, polish the surface and place the insoles in the boots.
12 Finally
will all
Boots still water-repellent impregnated and one last time
checked before
wrapped them up and
be shipped.
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