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Phunkie Badger Vellies - How our Vellies are Made

Handmade (Stitch Down & Cement Method)

  • 100% full grain leather & Hunting Suede (either full grain or hunting suede depending on the style) renowned for durability and strength, natural oils and texture, all our skins are hand selected to ensure we only get the best cuts to work with. After experiencing the soft comfort of leather vellies you wouldn't want to settle for anything less

What is the Stitch Down & Cement method ?

  • The leather upper comprising different pieces, according to style design, is sewn together and pulled over the last and flanged/turned outwards onto the non-woven insole and then attached to the insole first with adhesive and then what’s called a heavy stitch (ie using a thicker gauge thread for strength) using a specialized outsole stitcher.This is where the “stitchdown” process takes its name.
  • Glue is also used to help attach the upper to the insole (i.e to attached the non-woven insole to the TPR sole)

Upper - 100% full grain or hunting suede bovine leather

  • This leather gives maximum value for money in terms of durability, elegance and texture. It is also water and abrasion resistant
  • Water resistant, Cool and Strong
  • The leather upper is hand cut by a skilled operator using a metal press knife using a clicking press machine

Insole

  • The insole is a non-woven board which is thicker and stronger than cellulose (paper) insole board used in conventional footwear. We use a high quality non-woven insole board (as opposed to cheaper non-woven boards available in the market).
  • PU lining attached to a foam layer (for comfort) is used for the insole sock inserted after the shoe is made

Sole

  • TPR sole  (TPR is a thermoplastic rubber compound which is injection moulded)
  • TPR soles offer superior comfort & durability. They are flexible, like a traditional leather sole, but more durable especially for wet conditions
  • TPR soles offers traction and retain elasticity in cold and warm temperatures.

Adhesive products used in building the shoe:

  • Uppers are glued together using adhesive and then stitched.
  • Insoles are glued to upper and then stitched  - method is called STITCHDOWN.
  • Shoes are hand lasted (We hand last our Vellies where the assembled upper is pulled over the shoe last and pressed with adhesive onto the insole before stitching it together with a heavy stitch but the last always stays in till the end of the process and the last is only slipped off the last once the vellie is complete ensuring the shoe keeps its shape throughout the process.
  • Hand lasting takes slightly longer than force lasting (where the shoe last is only inserted after the upper/insole is closed) but gives a superior product
  • The TPR soles are cemented using adhesive that is heat activated and then pressed together with the upper/insole in a pressurised sole press to guarantee secure bonding.