Explorer Hiking Staff Kit: Build Steps and Finishing Tips
By Tandy Leather — Tandy Leather, Inc. | Published: 2026-10-16
Category: How-to Guides
Follow these steps to assemble the Explorer Hiking Staff Kit, from prepping the pre-punched leather to finishing the wrap. Get a solid hiking staff build with fewer mistakes.
Quick answer
The Explorer Hiking Staff Kit is a pre-cut, pre-punched leather wrap that fits a 1-1/8" diameter hiking staff. To build it, you'll lace or stitch the leather around your staff, then finish the edges and seal it for weather resistance. Expect a Level 2 project that takes a few hours and basic tools. The kit includes the leather parts, but you'll need a staff, lacing or thread, and a few finishing supplies.
What you'll need before you start
The Explorer Hiking Staff Kit comes with pre-cut, pre-punched natural veg-tan leather pieces sized for a 1-1/8" diameter staff. You'll also need a hiking staff or dowel of that diameter, a cutting mat, a mallet, and a stitching or lacing tool. For finishing, gather edge beveler, sandpaper (400–800 grit), and a sealant like beeswax or leather balm. A small clamp helps hold the leather steady while you work.
Prepare your workspace and staff
Work on a clean, flat surface with good lighting. If your staff is new, sand it lightly to remove splinters and wipe off dust. The kit is designed for a 1-1/8" diameter staff; if yours is slightly different, the pre-punched holes may not align perfectly, so measure first. A dry fit of the leather around the staff will show you where adjustments are needed before you commit to stitching.
Stitch or lace the leather to the staff
The pre-punched holes are spaced for a standard saddle stitch or whipstitch. Start at one end and work toward the other, keeping even tension. If you're lacing, use a single strand of lace and pull each stitch snug but not tight enough to distort the leather. For stitching, use two needles and a locking stitch. Check the alignment every few holes—if the leather starts to spiral, you've pulled one side tighter than the other.
Finish the edges and seal the leather
Once the leather is attached, bevel the edges with an edge beveler, then sand them smooth with 400-grit, moving to 800-grit for a polished look. Burnish the edges with a slicker and water or gum tragacanth. Finally, apply a thin coat of beeswax or leather balm to seal the leather against moisture. Let it dry completely before using the staff outdoors.
Explorer Hiking Staff Kit build steps
- Dry-fit the leather to your staff: Wrap the pre-punched leather around your 1-1/8" staff without stitching. Check that the holes align and the leather meets evenly. If there's a gap or overlap, your staff diameter may be off. Checkpoint: The leather should meet edge-to-edge without forcing. If it doesn't, measure your staff before continuing.
- Secure the starting point: Clamp or tape the first inch of leather to the staff so it doesn't shift. Begin your stitch or lace at one end, working through the pre-punched holes. Keep the first few stitches loose until you've established the pattern. Common mistake: Pulling the first stitches too tight, which causes the leather to pucker and misalign later.
- Stitch or lace with even tension: Work your way along the staff, maintaining consistent tension on both sides. For saddle stitching, pass the needle through each hole in a locking pattern. For lacing, use a single strand and snug each stitch without crushing the leather. Checkpoint: Every few inches, hold the staff up and look down its length. The leather should spiral evenly, not twist to one side.
- Finish the ends: When you reach the end, backstitch or tie off securely, then trim excess lace or thread. Tuck the tail under the last few stitches to hide it. If the leather ends overlap, bevel the overlapping edge so it sits flush. Common mistake: Leaving a loose tail that unravels with use. Always backstitch at least three holes.
- Bevel, sand, and burnish the edges: Use an edge beveler on all exposed leather edges, then sand with 400-grit followed by 800-grit. Dampen the edges slightly and burnish with a slicker until they're smooth and sealed. Checkpoint: Run your finger along the edge—it should feel rounded and smooth, not sharp or fuzzy.
- Apply a protective finish: Coat the leather with a thin layer of beeswax or leather balm, working it into the surface with a cloth. Let it absorb for 10–15 minutes, then buff off any excess. This seals the leather against rain and sweat. Next step: Reapply the finish every few months, especially if the staff sees heavy use or frequent moisture.
Kit details that affect your build
- Explorer Hiking Staff Kit: Fits 1-1/8" diameter hiking staff; Kit Level: 2; Color: Natural; Includes pre-cut, pre-punched leather parts. The pre-punched holes save time, but you must match the staff diameter exactly. Level 2 means some stitching or lacing experience is helpful.
- Dillon Bifold Wallet Acrylic Template: Dillon Bifold Wallet Acrylic Template includes full-scale pattern pieces, materials list, and assembly overview; finished dimensions 3.5" x 4.75" x 1"; recommended leather: 4-6 oz semi-firm to firm tempered (0.5 sq. ft.), 3-4 oz semi-firm (0.75 sq. ft.), 2-3 oz semi-firm. If you want to practice stitching before the staff kit, this template gives you a structured project to build skills with similar leather weights.
- Great Shapes Clover: Great Shapes Clover are pre-cut veg-tan leather shapes, 2.75" x 2.75", natural color, sold in packs; great for carving, dyeing, and creative projects. Use these as practice pieces for dyeing or carving before you finish your hiking staff, or add a decorative clover to personalize your build.
