Custom Cut & Sew

Custom Cut and Sew Services


We are proud to offer custom cut and sew services that bring you the best in American quality. Each custom piece is hand-crafted here at our shop in Bedford, Virginia. We strive to produce top quality custom products that will last a lifetime. To inquire about a custom project or service, email If you have a picture of your product, please include it. Remember that cut and sew manufacturing is a complicated process — however, the end result is a completely unique, customized-to-your-needs product.


We have manufactured for Tembo Tusk, LT Wright Knives, Sackwear, Overland Expo, Maxtrax and others.


Frequently Asked Questions

Can you make custom adjustments to a product you currently make?

We certainly can. As a disclaimer, however, it's important to keep in mind that even small adjustments or changes to a current product take a new pattern, more fabric, time, and labor cost to manufacture. Essentially, your custom project becomes a new product all it's own! Each custom product will be billed at an hourly shop rate. Please email us with your idea, product(s) dimensions, or drawings so that we can provide you a quote and time frame for the finished product.

What is the cost minimum for manufacturing services?

We don't have a cost minimum. We are just as happy to work with our clients with a single product as a company who is looking for a custom production run.

How much will it cost?

Our custom cut and sew services start at $50/hour, with a minimum of two hours time. Each product is unique in the amount of time, materials, and labor required.. We can offer you a price quote by providing a sample run of your custom product. We generally ask for enough materials to produce ten samples. From the sample run, we infer a time study which will help us accurately provide a price quote.

Depending on the complexity of the product, patterns supplied, specifications, potential order sizes, and product development time, a sample run typically costs around $200. For contract sewing work, the cost is $50/hour for sampling and pattern work, with a minimum of three hours. To get production pricing, we require a time study to make a sample of between five and ten units. Unit sample runs are built at $50/hour.

What if I have just an idea?

We are happy to help an entrepreneur get started! At Blue Ridge Overland Gear, we have a team of highly skilled designers and builders who can help you develop your project; taking it from “just an idea,” to a piece of functional gear that will serve you for years. If you have a new product idea and need a sample started from scratch, product development fees start at $400.00.

Do you provide materials?

Many customers purchase their materials and ship them to us, which helps save on costs. However, billed at an hourly rate, we can help you source your materials.

How fast will my sample run or order be done?

Each project has a different time frame. It all depends on the nature and complexity of your project. Another factor is how busy we are at the time of your order. Typically, sample runs can be completed in 2-4 weeks after materials have arrived. Finished orders can take between 6-8 weeks to complete. If you are ordering at the beginning of the Spring or Fall months, you may experience a slightly longer than usual wait.

What if I want to cancel my order?

Please contact us as soon as possible regarding any cancellation. Refunds for canceled orders are at the express discretion of Blue Ridge Overland Gear and its employees. Due to the custom nature, if we have already made progress on your order, cancellation will not be possible.