- 1). Decide on the style and the size you would like to make your chaps. Different styles include the Batwing, Chink, Cutting, Rodeo, Show and Shotgun chaps. All of these styles incorporate slightly different lengths, with flares or tassels along the seams, but each should cover the entire leg from the cuff up to the belt where they are attached.
- 2). Trace the outline of your selected style onto your piece of sheet metal using a marker. Remember that the design must incorporate both the front and back sections to the chaps. Make a template using a cloth sheet to help you if you are unsure of the design.
- 3). Cut out the chaps from the sheet metal using a pair of tin snips. Be careful of the sharp edges of the metal.
- 4). File all edges to a round edge with your file.
- 5). Bend the chaps to contour to the legs of the figure.
- 6). Secure in place by applying a small amount of glue with your hot glue gun on the inside top edge of the metal chaps.
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