1. Fabricate a Varus/Valgus Control Strap For an AFO
OR-PR 156 Task 7
Fabricate a Varus/Valgus Control Strap For an AFO

2. Reinforcing the Strap
Cut out your leather strap from the metal template and place it unfinished side up on the table
Cut a piece of 1/2” dacron tape the length of the strap minus 1” in from each end
Cut the strap where indicated almost, but not completely, through the tape
Glue the tape down on the strap as shown

3. Padding the Strap
Turn the strap over finished side up

4. Padding the Strap Turn the strap over finished side up
Place a piece of 1/8” soft foam underneath the strap as shown
Trace around the strap as indicated
3/4” 4”

5. Padding the Strap
Cut out the traced shape

6. Padding the Strap Cut out the traced shape
Sand the edges where shown creating a 1/4” bevel

7. Padding the Strap Cut out the traced shape
Sand the edges where shown creating a 1/4” bevel
Turn the strap unfinished side up, turn the pad over and glue it to the strap

8. Padding the Strap Sand the edges of the foam flush with the strap
Bevel the edges back 1/4” on the sides and 3/4”-1” up from the bottom

9. Lining the Strap
Turn the strap over finished side up

10. Lining the Strap Turn the strap over finished side up
Fold the foam over the top edge and glue down
Stretch and glue a piece of cream cow to the unfinished side as shown

11. Lining the Strap
Make (2) cuts in the cream cow as shown 1/4” to the outside of the foam pad
1/4”
1/4”

12. Lining the Strap
Fold the cream cow down over the pad and glue

13. Lining the Strap Fold the cream cow down over the pad and glue
Sew the cream cow to the strap as shown

14. Lining the Strap Trim the cream cow from the strap
Now trim the cream cow along the edge of the foam pad

15. Attaching the Buckle and Billet
Cut out a leather billet to these dimensions
A 5/8” buckle will be used
1 3/8”
1 5/8”
7/8” 1”
5/8”
5/8”

16. Attaching the Buckle and Billet
Skive the ends on the unfinished side

17. Attaching the Buckle and Billet
Slip the billet through the buckle and glue down
The ends will be staggered as shown
Bottom
Top

18. Attaching the Buckle and Billet
Place the billet on the strap so that the end of the buckle is 1/2” back from the edge of the strap
Once the billet is sewn to the strap the project is completed
END