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A template for the gusset.

Note that I am using a Fiskers rolling cutter, which is a wonderful to use, allowing great precision when cutting leather or cloth. It is far preferable to scissors or a knife. Cuts are taken on a dress patternmaker's plastic surface, which is very handy.

I am using a two-piece gusset, glued together for air-tightness. The two materials are a very thin pigskin leather for the inside of the gusset, and nice upholstery leather for the outside. Both are glued together with flexible rubber cement, like "Barge" cement, providing an airtight gusset with no seasoning needed.

This is a bit of an experiment. I would have preferred a single-layer airtight gusset, but could not find air-tight chrome elk-tanned" leather as is used in bagpipe bags like those from L&M. If anyone knows of a reliable source of pipe-bag leather (other than Tandy / The leather factory) let me know.

Update-- so far this two-layer approach is performing well. Perhaps the gusset is a bit stiff, but the leather is softening as I use the bellows and does not appear to be a problem. I'm not sure about the long term durability of the glue, but so far so good.