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Advanced Custom Rod Building
Step 1: Introduction
Step 2: Time
Step 3: Cleanliness
Step 4: Finish Resins
Step 5: Thread
Step 6: Test Your Materials
Step 7: Starting
Step 8: The Blank
Step 9: Reel Seat Position
Step 10: Rings
Step 11: Working With Thread
Step 12: The Finishing Touches
Step 13: Thread Art
Advanced rod building is probably a poor description of how to build a fishing rod. At a basic level, the 'rod builder' selects a rod blank, he adds rod rings, handle, reel seat, adhesives, finish resins and thread. The basic components of all fishing rods, put them together in the correct order and you have a finished rod. In the manufacturing world this can mean several hundred rods all looking the same, with the same colour thread, same style or type of rings etc., etc., |
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Do not look to build a rod over night. There are plenty of stories of rods being built in one or two days, read the instructions on some finishes, they are touch dry in 6 hours, harden in 24 hours and fully cure in anything from 6 to 14 days and how many coats of finish are you using? |
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To the manufacturer with large drying rooms and dust control systems this is comparatively easy. I would not like to say just how many times I have had to deal with dust particles, midges or flies being encased in the resin finish. |
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These will test your ingenuity. All resins, either one or two part are self-leveling. Thus when you put the resin on a round blank it will run to the underside giving a 'tear-drop' effect. |
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Thread has two prime uses. 1. To hold rod rings to rod. 2. Decorative work to create an individual and distinctive rod. Thread is available in various grades of thickness; do not assume that you need the thickest available for sea rods and the finest for fly rods. Modern resins, which are derivatives of epoxy glues, permit fine thread to be used, as the resin will anchor the rod ring to the rod. |
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If the product is new to you - test it, there is nothing worse than spending many hours getting the rod to look right than to find a new finish wrecks the effect you are trying to achieve. This is specifically important with thread, colour sealants and resin finishes. Short lengths of dowel or broom-handle are in valuable as the material on which to build test items. Remember the colour of the rod blank will also affect the finish colour of the thread when you have either a light or dark colour blank. |
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Having chosen your blank and given it a good clean examine it for imperfections. They maybe slight but nobody wants the blank to explode on the first fishing trip. When you are completely satisfied set about choosing the following items. Reel seat - make certain the hoods will fit over the foot of the reel. (Yes I've been there, the customer changed the model of reel and I had to cut off and fit a brand new reel seat!). Select a set of rings best suited to the style of fishing the rod is to be used for and within the price range. I mentioned price range as a plain metal ring will wear quicker than a lined ring and the lined ring will cost progressively more as the overall quality of the 'liner or insert' increases. There are many excellent ranges of rod ring manufactured around the world, top of my list Fuji and Seymo. You now have you all the items you need to complete the rod. Good now we can start the preparation. |
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If you search the Internet you will be able to hear or read every convincing argument for and against building a fishing rod 'On the spine'. I have listened to too many and fall in the camp of working with the spine of a rod. I will not dwell on it here. Have a read then make a decision on what you want from your fishing rod. |
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Thankfully we are all different and contrary to belief, a short person may prefer a long reach on the handle of a surf rod whilst a taller person may like a short stubby hand reach. On a fly rod do you want the reel seat thread up locking or down locking? It will radically effect how you balance the rod at a later stage. Once comfortable set the reel seat in place using arbors for packing and a priority adhesive. Leave to one side for several days to set, then twist and tug on the reel seat to check it is firmly in pace. Now fit the handgrips, again permitting the adhesives to set fully. |
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Check them for damage or marks. Do you have a grinding wheel on a lathe or similar, as you need a very fine abrasive disc to work on the tip of the ring foot or feet. Hold the ring upright on the blank, do both feet lie flat on the rod, if not gently bend the frame so they are flat to the blank. Now grind the tip of the ring foot to give a smooth shoulder to the foot. This will permit the easy transfer of the thread over the ring foot without it jumping and looking unsightly. After grinding and polishing smooth, should the tip of the ring foot be bright metal you can blacken or colour it. Test that the colouring agent does not bleed through the thread when finish is applied. |
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You have chosen the colour and tested how it will look used with or without colour preserver. Do not be miserly with thread; it will give the most visual effect at the end of the day. Cut out blemishes, metallic finish thread can 'rough up or fragment' with a blink of the eye. If it happens, cut it off and start again. |
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The 'Seymo' logo woven here was achieved at the second attempt and from drawing the original pattern to completing the finished logo took some 14 hours. Threads used are Fish Hawk 'A' thread for the Green, Metallic Green and Orange with Gudebrod 'A' Thread NCP White. Both the test work and this finished logo each contained over 140 threads worked on special 'rod looms' available only from the USA. Another example is in my boat rod 'Red, White & Blue'. See photo at top of this page. Here the Union Jack flag is again woven, this was some 24 hours work through development to finished flag. Wraps are somewhat easier and these are photographs from Conferences I have attended in the USA in recent year. The originators of the work are unknown. One other specialist effect is to put pictures into EVA foam handles. The result can be seen in the photograph of 'Red, white and blue' where the Union Jack flag has been inlaid into a red EVA grip. The USA has a master of this work, Bernie Cohen from Brooklyn, New York State. He has permitted his work to be displayed here and it clearly reflects the true 'artist' at work. |
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