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Patterns
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The best pattern to sew a new saddle pad is to disassemble an old, worn-out but well-loved saddle pad. Observe that number of layers of padding and composition of the padding as well; likely, they are cotton, synthetic fleece.
Barring that, only one commercially-available pattern seems to be available, from Seattle Fabrics (see Resources). This company has a wide selection of patterns for both riding kit and horse gear, including jodhpurs and chaps, fly masks and feed bags.
Finally, you can get by with a perfect rectangle. Lay your shell material on the horse̵7;s back, put the saddle on the horse. Trace a big square that leaves three to four inches on all sides of the saddle, such that no part of the saddle would touch the horse̵7;s flesh.
Plan to make the pad thicker in the center, with two or more extra layers in the middle of the saddle. As veterinarian Joyce Murdoch told the website Horse Channel, "To distribute the saddle's pressure as evenly as possible, western pads should fill in the middle as opposed to making a bridge between the front and back of the saddle.̶1; Ideally, the finished pad supports the bridge.
Regardless of the pattern you choose, you must quilt the finished pad with some running stitches from front to back, or in a diamond pattern, to prevent the padding from bunching and distributing pressure unevenly.
Materials
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The pad must be durable and washable, and must ̶0;breathe̶1; to protect the horse̵7;s flesh, which will guide you in your selection of materials.
Most commercially-available saddle pads have a wool felt underside, or sometimes fleece.
The top side (facing the saddle) can be any material from rip-stop nylon to canvass duck to wool to corduroy. A natural fabric like wool provides better sweat-wicking properties than a heavy synthetic.
Finally, use synthetic fleece in several layers (five or more) interspersed with cotton batting for the padding.
Final Fit
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First, be certain that the saddle fits well. ̶0;Adding more padding under a saddle that doesn't fit right is like putting more socks inside a tight shoe,̶1; writes Jennifer Warner on Horse Channel.
Use the pad on a ride, and run your hand over the horse̵7;s flesh afterwards. Feel for hot spots, which indicate pressure points. Here, you may wish to remove a layer of padding, or, build up the padding in the areas around the hot spots.
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Instructions to Make a Western Saddle Pad
There are surprisingly few resources for making western saddle pads. These are the pads that sit between the saddle and the horse̵7;s back, which add cushioning (for the horse̵2;not the rider). A saddle blanket fills the same purpose. Still, there is nothing terribly complicated about western saddle pads. They are at their simplest a thin cushion filled with synthetic and cotton padding, and quilted with stitching to prevent bunching.