Orr Pantaloon Overall project with Dean Hashimoto!

We started this project over a year ago with the aim to study and reproduce an extraordinary pair of late 1860s - early 1870s pantaloon overalls in Dean's collection. We analyzed and discussed the construction, materials, and measurements in great detail via hundreds of photos, endless DMs and online conferencing over several months. We had to put the project on hold multiple times as work got in the way, but we managed to create a prototype in November last year. This allowed us to compare all the details again and make many adjustments to the pattern and corrections in the construction, culminating in this final version.

Our aim was not so much to create an exact clone of the original pair in Dean's collection, but rather to create a new pair that could plausibly have been made around the same time at the same factory, using the same construction methods and the most authentic materials and parts that we could find. Through this process, we wanted to gain a detailed understanding of the creativity and ingenuity that went into the production of this garment during a fascinating period in the history of American work wear.

We were very lucky to be able to source the perfect 11 oz mock twist denim for this project, just enough for this one pair! In mock twist denim, the weft is formed by combining one white roving and one black roving prior to the spinning operation. Combined with the indigo-dyed warp, this creates the characteristic appearance on the backside of the denim. The denim shrinks about 8% along the warp and 5% along the weft, and the pattern was calculated to hopefully result in the same measurements as the original pants after several washes.

The new-old-stock "PATENT 1855" steel buckle and 1877 trade mark "pantaloon buttons" are perfect matches for these pantaloon overalls. We were really lucky to find these online at just the right time.

#sweetorr #pantaloonoveralls #collaboration #notforsale
Orr Pantaloon Overall project with Dean Hashimoto!

The final couple of steps -- making the top button hole, sewing on the top button and suspender buttons, and finally, the hemming.

#selfmadevintage #handcraftedjeans #1870s #sweetorr #pantaloonoveralls #collaboration #eurekajeans #forover30years #justahobby #notforsale
Orr Pantaloon Overall project with Dean Hashimoto!

With the waistbands attached, the pants are nearing completion.

#selfmadevintage #handcraftedjeans #1870s #sweetorr #pantaloonoveralls #collaboration #eurekajeans #forover30years #justahobby #notforsale
Orr Pantaloon Overall project with Dean Hashimoto!

With the outseams closed, they finally turn into a pair of pants.

The spread selvedge seams are somewhat uneven, ranging from 1/2" to 3/4" in width.

#handcraftedjeans #selfmadevintage #selvedgedenim #1870s #sweetorr #pantaloonoveralls #collaboration #eurekajeans #forover30years #justahobby #notforsale
Orr Pantaloon Overall project with Dean Hashimoto!

With the inseam done, the front and back panels have been connected.

The inseam consists of two rows of stitching overlapping for about 8 inches on either side of the crotch, continuing into a single stitch along the rest of each leg. The benefit of this method is twofold; starting the sewing near the crotch makes it easier to perfectly align the center seams of the front and back panels (as shown in the last photo), while the resulting overlapping stitches form a double seam that reinforces the crotch area (as visible in photos 3 and 4).

The raw edge of the inseam is overlocked by hand along its entire length.

#selfmadevintage #homemadejeans #1870s #sweetorr #pantaloonoveralls #collaboration #eurekajeans #forover30years #justahobby #notforsale
Orr Pantaloon Overall project with Dean Hashimoto!

The fly construction.

For most jeans, the fly is installed before closing up the crotch seam, but for these pantaloons, the order is reversed. This is one thing I got wrong in the prototype I made some time ago.

As with all other parts of these pants, the fly area has a lot of hand sewing. The raw edges are overlocked by hand, the button holes are hand sewn, and the fly is attached to the front panel by hand in four places, which creates separate compartments for the button holes.

The iron buttons we're using on this pair are real vintage deadstock from the 1870s.

#selfmadereplica #homemadejeans #1870s #sweetorr #pantaloonoveralls #collaboration #eurekajeans #forover30years #justahobby #notforsale
Orr Pantaloon Overall project with Dean Hashimoto!

The characteristic front pockets are done. The pocket bags are made of the same denim as the rest of the pants. The bags are closed with a double overlapping row of stitches, and the seam is overlocked by hand.

#selfmadevintage #handcraftedjeans #1870s #sweetorr #pantaloonoveralls #collaboration #eurekajeans #forover30years #justahobby #notforsale
Orr Pantaloon Overall project with Dean Hashimoto! Attaching the cinch straps and back pocket to complete the back panel. The pocket is a 6 1/4" by 6 1/4" square when raw, but will shrink to 5 3/4" in length by 6" in width after washing. It has a rectangular reinforcement on the upper left-hand corner, but not on the right-hand corner. #selfmadereplica #handcraftedjeans #1870s #sweetorr #pantaloonoveralls #collaboration #eurekajeans #forover30years #justahobby #notforsale
Orr Pantaloon Overall project with Dean Hashimoto!

Sewing the back center seam. All raw edges on these pants are overlocked by hand.

The back panels are first stitched right sides together, starting at the split back to create a plain seam all the way down to the inseam. The fabric is then turned 180 degrees to sew back 1.5 inches in the opposite direction, curving toward the edge of the seam. This reinforces the seam in the crotch area. After overlocking the raw edges by hand, the right back panel is folded over and topstitched through all layers.

#selfmadevintage #homemadejeans #1870s #sweetorr #pantaloonoveralls #collaboration #eurekajeans #forover30years #justahobby #notforsale
Orr Pantaloon Overall project with Dean Hashimoto!

Starting with my favorite part; the back cinch.

The straps are machine-sewn, but the buckle is attached with hand-sewn stitches.

We're using a vintage period-correct buckle for this pair. It has "PATENT 1855" on the back. The size and shape are very close to the buckle on Dean's original 1870s pair.

When making the prototype, I thought that each strap was made of two pieces of denim, but upon closer inspection of the photos, I realized that they were made of a single piece of denim, so that's one of many corrections I'm making on this final version.

#selfmadevintage #homemadejeans #1870s #sweetorr #pantaloonoveralls #collaboration #eurekajeans #forover30years #justahobby #notforsale