If you're going to turn your horse out in a nyion halter, be sure it has a good breakaway system, like the one on this BMB halter (www.bmbtack.com, 800-842-5837).

Washing and Cleaning
Nylon halters, headstalls, reins and lead straps can be put in an old pillowcase with the end tied shut with string and washed in a washing machine with a load of laundry (such as jeans) that’s not fragile nor white.  The pillowcase tends to trap hair and dirt and protect the enamel on the inside of the washing machine from being banged by halter hardware or snaps.  It also keeps halters, lead straps, etc. from getting tangled up, as they do when washed loose. 

When the load of wash is finished, take the tack out and give it another rinse under a faucet or hydrant to make sure there’s no soap residue, then hang outside to dry.  The dirty pillowcase can be turned inside out and rinsed, then put with a regular washing.  To make a sack with more cushion than a pillowcase, fold an old bath towel in half and sew two sides closed.  Add a drawstring or Velcro to the open side to make a handy bag for washing nylon tack.

Frayed Edges
If a web halter starts to fray along the edges, wash it in the washing machine and while it’s still damp after the spin cycle, singe frayed surfaces and edges with a cigarette lighter or matches.  The heat will burn off the friz but won’t hurt wet webbing.  If a nylon lead rope is frayed on the end, melt the frayed portion in the same manner--melting the frizzy ends back into the rope.  Caution: When using matches to do this, do it over the sink, in case you have to drop a match or douse a hot spot.

Adding Holes
If you need more buckle holes in a nylon halter, headstall or any other piece of nylon tack, a leather punch alone is inadequate because any cut surface tends to fray and break down.  Use a leather punch to make the pilot hole, then melt the material around the hole to seal it, using a soldering iron, woodburning tool or hot nail of proper diameter.  You can also use a hot nail to clean up an existing hole that has become frayed.  If you melt the hole from one side and then the other, it will make a neat, smooth hole that will keep its shape and not fray.  Wear thick gloves or an oven mitt to hold the nail by the head with pliars while you heat the tip over a gas stove burner or some other safe source of high heat, then immediately poke it through the nylon to seal the hole.  If you don’t have a leather punch, a new hole can be created this way; if your nail or soldering iron is hot enough it will melt right through.  It’s easiest, however, if you have a pilot hole first.