From start to finish, here's how your ropes are made.
How It's Made
Boxes of materials arrive at our warehouse.
The materials are spun into rope bodies.
High quality threads from around the world arrive weekly.
Various combinations of materials are threaded onto the hooks of a specialized machine that then twists the threads into either three or four strand rope bodies. The bodies are kept in sets, and moved to the side.
This process is for team ropes and ranch ropes (nylon and nylon/poly blends) made right here in Idaho.
Almost every rope we make uses white thread, but we have thread in almost every color of the rainbow!
The wax process affects the finished color of the ropes. These are blue Gator Fource bodies (above) before the wax, and a finished Fource that is ready to ship (left). Wax affects the colored threads differently. Some colors will be darker, and some will bleed away or onto other threads.
The rope bodies are dipped in hot wax.
Each bundle of bodies is imersed in our thermostatically controlled wax vat. The wax process gives the rope both body and memory.
Blocks of wax before they are melted in the wax vat.
The bodies are stretched, and then set aside to relax.
Once removed from the wax, the bodies are hot stretched and then set aside to cool and relax.
The hondo is tied, and the rope is stretched for a second time.
Each bundle is moved to another facility where our experienced employees hand tie each hondo (eye). They then stretch the rope again, this time to tighten and set the eye.
The burner is sewn in and the tail is finished.
The employees then hand sew a rawhide or leather burner into each eye, and finish the tail. A team rope will be given a shrink tag, and then tied with a single crown, where a ranch rope will be sealed with a shrink tag and the end will be melted.
The ropes sit overnight.
The ropes spend the night laying on the floor. This is a very important as time allows the crowns to relax and return to their original positions. Skipping this step and coiling the rope immediately, leads to ropes that swing inconsistently among other problems.
Tying a tail knot.
Sewing a burner.
The ropes are coiled and secured with twist ties.
One by one, each rope is threaded and coiled by experienced employees who operate our exclusive coiling machine. The rope is given a specific amount of kick, coiled up to a consistent size, and secured with twist ties. Our exclusive coiling process eliminates variations from batch to batch leading to more consistent ropes throughout the year.
Ropes are placed on storage racks, waiting to be shipped.
Rubber gators are placed on our Gator team ropes. Other ropes, such as Rocky Mtn. Ropes, receive our new informational hang tags.
Some ropes receive gators, other receive hang tags.
Our products has been shipped to every state in the nation and over 20 countries.
We stock over 300 different styles of ropes. When an order is placed, the ropes are pulled from the shelf and sent out to the customer.