Whilst the senior cutter at Huntsman, David collaborated with the costume designer Susannah Buxton on series two of Downton Abbey, to create the "Dress Tails" for the character the Earl Of Grantham, played by Hugh Bonneville. Using archival references of dress for the era, David was able to create a piece that was accurate for the period in which the programme was set. Shown below is the actual illustration that was used as a reference to guide David in creating the garment for the programme. The illustration was sourced from the book by J.P. Thornton "The International System of Garment Cutting" which was first published in 1910 and was the starting point for cutting the pattern. Three and a half metres of medium weight black Barathea was used to make the dress tails. Slightly more cloth was ordered than usual in case the the garment was damaged in some way during its creation, allowing additional pieces to be cut from exactly the same length of cloth if needed.
Much consideration was paid toward many of the nuances of the period that would make the garment as authentic as possible so David could create an item of clothing that would be aesthetically correct. For instance, no sleeve wadding was used in the sleeve heads of the garment which is usually a signature in a Savile Row suit. As you can see in the image of the final finished garment, the shoulder ends are slightly softer compared to a modern dress tails if made today. Also included is a picture of Hugh Bonneville during the first fitting of the dress tails. As well as making sure that every aspect of the garment was correct from the requests of the costume designer, David also had to take on board the needs of its wearer, as Hugh Bonneville requested that the trousers be made without any pockets, to keep him from putting his hands in them whilst filming on set.