While I’m hoping that I can avoid this, I may be in a situation where I need a truly custom saddle from the build of the tree up. I have an ungodly large Hanoverian gelding who has an incredible amount of bone. His issue is NOT tree size; he fits very comfortably into a 33 or 34 cm tree depending on the cut. The issue is gullet width and the shape of the panels. In order for this horse to have appropriate clearance of the spine itself and for the panels to be balanced over his latissimus dorsi, the gullet of the saddle needs to be almost 6.5 inches. The panels also need to be cut on a bias. I am working with Prestige at the moment and my rep (who is also a master saddle fitter) thinks that there is one model they MIGHT be able to modify to make the gullet wide enough, but if this doesn’t work, she’s at a loss and suspects I’ll need to find someone who builds a fully custom saddle. The issue as explained to me is that the panels can only be set so far apart on the tree for the balance point and that going beyond that would make the saddle unsafe for both horse and rider. So what I may very well need is for a master saddle maker to custom make the tree so that the panels can be set further apart and then build the saddle from there. I just don’t know of ANY companies that offer this option. I’ve already spoken to County, Black Country, and Stackhouse, all of whom have the same limitations in regards to gullet widths. Any ideas would be greatly appreciated!
This sounds like a hoop tree situation - BC used to make one. Maybe I missed it but have you sent pics and tracings to a company that definitely makes hoop trees?
IME Stackhouse is about as custom as they come BUT their saddles are historically narrow types, at least the few I’ve seen on the market used.
Anyways, the width of the gullet sounds like hoop tree territory, though the rest of it I’m not familiar with exactly and might have different names from maker to maker. Regardless, it is true that a saddle that fits this type will never feel like an A frame French-type foam saddle to the rider.
I believe Hermes will but it will cost a whole wheelbarrow of arms and legs and I’m afraid it’ll be prettier to look at than functional to ride in.
I think a good fitter could get something done using Black Country or possibly Hastilow to make the saddle from scratch from the (many) available options. But that’s not truly bespoke. You said you spoke directly to BC and they were skeptical but I think if a fitter sketched out exactly what she wanted and had them look at that you might get some different feedback from them. It might be more doable than she thinks.
Yes, I’d second the hoop tree idea.
You might also look at Frank Baines saddles, some of which have a hoop tree.
Have you investigated Patrick Saddlery? I’ve seen them build things for horses that the owners had given up on.
Harry Dabbs—although they’re most known for their work fitting TBs—can get REAL custom with fit. They do not mind odd change orders.
Might be worth investigating.
Hastilow did a completely custom saddle for a friend to fit her extra thick Clyde cross. I’d reach out to them.
I know one local in No. California: Shamss, his company is Gravity Saddlery: https://www.gravity-saddlemaker.com/
The people I’ve known who bought his saddles were happy withithe saddles and process, but they did in person fitting. I don’t know anyone who worked with him remote.
@vxf111 coincidentally he used to work for Hermes
Why can’t BC do a hoop tree?
I have a WB with a huge back and BC was one of the options.
BC can definitely offer a hoop tree in lots of models. I’ve seen plenty.
Not an answer RE: truly custom saddlers, but have you looked into Duett? I had a friend with a spectacularly enormous, truly old school type of guy (blanket was an 86 and it wasn’t just length, the bone on him was unimaginable) and the duett worked well for them. The company’s whole approach is specifically targeting people with wider horses so even if they don’t have something off-rack that suits, maybe they would be a good resource for where to go next?
OP I’m wondering if some of your struggle is a communication error between parties - I’m not saying there aren’t horses out there that just won’t fit in a semi custom saddle, I’m just saying they’re extremely rare. Have you sent off pictures and tracings or is the fitter doing the legwork?
It sounds like the horse doesn’t need “wide” in the way A frame or gullet plate saddles are “wide” - aka just adding more angle to the tree points - but he needs more clearance for his spine and other structures. An upside down U vs an A, usually done in a hoop tree. A lot of the brands listed above are known to do these (and I was pretty sure BC does as well, they’re pretty customizable, but OP said they’d talked to BC with no luck).
There’s an Australian brand that does a unique shape of tree that some people I know have enjoyed for their Bulky but not Wide horses. I can’t for the life of me recall the name, but it has a wide, almost paddle shaped tree point and supposedly is infinitely adjustable. Could be worth a try, if someone can recall the name 
You could check in with Heritage Saddlery in the UK as well: https://heritagesaddlery.co.uk/
I would look into Bliss/Loxley. I have two horses in hoop trees and they have multiple tree types and panel configurations.
We’ve had good lucky with hoop trees for our very wide gyspies. I currently am riding in 2 extra wide hoop tree Smith Worthington saddles- their stellar altaire model. Black County has hoop trees too.
Another vote for Shamms at Gravity. He’s a fabulous person and very dedicated to his work.
Thank you everyone! I have reached out to Gravity and am hoping that they’ll be the answer for us!
Out of curiosity, who did you talk to at BC that told you this wasn’t a possibility? It conflicts with what I know about them and what I have been told.
I have 2 BC saddles, both are genuinely custom - as in custom trees based on a template wither tracing.
I am on the cusp of ordering a third, for a horse who has a similar configuration as OP. I was told she needs an xxw (hoop) tree, and she has a similar spine clearance requirement. She is broad. Works fine for me, considering she is so wide it’s like sitting on a recliner. 
Kate Ballard of Westhill and Son offers custom made saddles.
She came to Ocala in the spring to fit a saddle for me and I was very happy with her service and knowledge. She is a master saddler and also had a lot of saddles available to try.
At that time she told me that she is in Ocala about once a month.
WOW Saddles.
