Panel Evolution
By Cindy Walters

The First Panel System: The System I patent (6/26/1986-USA) the inventor of the paneling systems was Len Brown of Brown Performance Saddle Company started in 1982. In 1986 Len
incorporated his business and became known as Ortho Flex Saddle Company.

The System I patent (6/26/1986-USA) is the very first panel developed by Len Brown. It is a single layer of .093 delrin and will fit a large number of different shaped backs. It allows for shoulder rotation but does not flex the full range of the back. The panel was mounted with a wood screw and a washer directly into the tree. The System I was an improvement over traditional saddles, but it did not allow the panels to flex downward in the center with the horse’s back, and the stiffness of the panels had to be adjusted to compensate for the rider’s weight, so with the problems arising from System I, Len was already developing System II.

The System II Patent (8/15/1991-USA) began in 1990.
System II offered a mounting system for the panels. With the panels mounted with bolts and a slot in the rear so the panels could actually flex with the movement of the horse. In System II the panels are moved away from the tree about 1/8" to 3/8" on steel rocker spacer mountings. Using three layers of Delrin at the mounting, where each one is successively smaller, creating what is termed as "progressive loading" or a load-distribution on the entire surface. System II can rise or sink with the horses back. This system had its problems too so Len always looking to improve was developing the next system.

System III is patented (2/18/1994 -USA), there are no laws or patents to protect the current System III, which was put into production.) System III was based off of System II and was changed in the front of the panel and looked like a large hand with 5 fingers. The fingers allowed the panel to conform more to the movement and the horses shoulder.

Pro-adjustable System IV (no patent) . Known as the high-tech breakthrough in flexible panel systems. The height of the panel mounting points can be adjusted quickly and easily with the use of an Allen wrench within a one-inch range. The problem with this system was that the adjuster would move up and down and would not stay adjusted.
THE "LICENSE": This license from the Original Ortho-Flex Saddle Co. was sold to "Rocking"R". This system is a hybrid of Ortho-Flex Systems I and System II. The system does not have the mounting in the front but offers the track system at the back of the panel. The system does flex and with the adjustable rigging can conform to several backs.

Mock VI or "Mock 6" MODIFIED EXTRA: by the Ortho-Flex Saddle Works Company, (which bought the original Ortho-Flex Saddle Co. and the rights to use the "Ortho-Flex" ® trademark name) This system has taken the rivets out of the Original Ortho-Flex System III and replaced this design with a flower petal pattern in both the front and rear.

THE ULTIMATE: American-Flex® System V patent (3/9/2001-Europe # EP1292316A2): The front of the panels are made of three layers, with 15 separate fingers. The second layer has six fingers, overlapping the first and enabling equal distribution of weight along the entire length of the panel, including the middle section and a third layer with no fingers. Every layer is smaller than the layer before. Construction was also changed in the rear. This design has also three multi layered construction; the second layer resembles that of two fingers flowing towards the center of the panel, to insure optimal weight distribution–including the middle section. This design, uses various sizes and thickness of Delrin are computer-calculated and curved, insuring that this system gives optimal distribution of weight along the entire length of the panel, both inside and out.

System VII (based on System V patent 3/9/2001-Europe # EP1292316A2): System VII added adjusters. This was virtually a knock off of the original Ortho Flex Pro adjuster using the System V delrin design. The adjusters were easy to adjust but just like the original Ortho Flex adjusters, they too would not stay adjusted.

Easy Slide AMERA-FLEX Panel System by El Dorado Saddle.
After repairing all of the above systems over the past 26 years we have come up with a better mounting design. The pop rivets in the System 5 and System 7 wear and break off and then would in turn cause grooves to wear in the delrin panels and would literally cause the panels NOT to flex. Also the adjusters were a good idea but then it too had its disadvantages. The customer was then able to raise and lower the front of the saddle, sometimes we found that they didn’t use the lock tite and after repeated efforts of trying to keep the saddle adjusted ended up sending the saddle in for repairs .

EZ Slide AMERA-FLEX Panel System by El Dorado is a multi layered delrin, multi fingered design. This panel has cuts and feathering in the top area along the spinal processes of the withers, and has a rounded front, making it more comfortable for all different kinds of horses. We have 3 layers of delrin and 1 layer of stainless steel in the rear, for the washer to slide on. After many years of repairing saddle we found that when the washer was able to wear a groove in the delrin the panels would not flex properly. Also we changed the pop rivets to the copper rivets. We also found that the pop rivets break after time and wear. The copper rivets lasted twice the amount of time and wear of the riding time. This will eliminate the wear spots in the delrin, which in turn will increase the life of your saddle. We changed the mounts, the washers, and the bolts. The washer has more freedom of movement and will not cut into the delrin panels. As we continue with repairs on all makes and models we will continue our quest for perfection.

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