No More "Clown" Toe Caps.

How to cut them down to size.

One of the complaints about some pairs of chucks, is that the rubber top caps are too inconsistent in size, and that they often are too big. Although this complaint was first associated with chucks manufactured in the 1990s, it isn't just confined to those years of chucks. With new production coming from several Asian countries, the same inconsistencies have continued to occur.

What we are talking about is the look of the toe in relationship to the starting point of the canvas uppers. In a well made pair, the toe cap cuts off in a straight line from edge to edge. But in many pairs the toe cap continues inside the tongue area, resulting in an out of proportion toe cap, the so-called "clown" toe. Let's take a look at two pair of shoes, both with the "clown toe cap" problem. The left pair was made in China and the right pair was made in USA in the 1990s.

But the problem is easy to fix for made in USA pairs. All it takes is a sharp knife, a sure hand, and some patience.

With the sharp knife begin cutting a straight line across the toe cap from the start of the left canvas upper to the start of the right canvas upper. (example 1) Be sure to work into the rubber with the knife so a groove is made, and use your other hand to support the toe cap from underneath. Be careful not to cut into the canvas. Eventually you will make a breakthrough in the cut when you reach the canvas. (example 2). Work the cut completely from edge to edge. Then begin to pry away the rubber you are cutting off. A small slotted screwdriver may be helpful at this stage. The rubber should separate away from the canvas, and eventually you should completely remove it. There will be a little residual glue at the outside edge of where the removed rubber piece was located. This can be scraped away, or just left, as it is hardly noticeable. See the finished results for both a black and red pair of chucks (examples 3-4).

Unfortunately, this precedure doesn't work well for made in Asia pairs. The rubber and/or glue composition is different, and the rubber doesn't pull off in one piece. It would take major scraping to remove all of the residual rubber, and is probably not worth the effort.

This procedure is not recommended unless you feel comfortable working with sharp knives or tools, and at this point only for made in USA pairs.

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