I don't think I have a saddle maker in my area--just a tractor supply store. I've tried looking for custom headstalls online, but couldn't find anything. Are there people out there who make them?
I think a draft bridle would be too large for him--my gelding is about 1300 pounds. Not quite an average horse, and not quite a draft. I guess not enough people ride warmblood sized horses western.
I've tried punching holes in his bridle to help it fit. His throatlatch just barely stretches to latch with the hole punched right at the end of it--it is way too tight to be comfortable for him. I've tried using a buckle dog collar as an extention of the throatlatch, but that was really akward (and it didn't solve the tight browband problem much).
Right now I've converted a old one-eared headstall with a twine and rope browband and throatlatch into something that sort of works for him. I'd really like to get something more perminant (and more durable!) though.