,t/,

BUILIiING THE BAMBOO FLY ROD

. _ .-_
 r

REVISIONS

Original Issue _______----_________~~~~--~~~~~~~~ Oct. 13, 1965

First Revision -----_______________~~~~~~~~---~-- Feb. 14, 1967
Second Revision --__________________------------- Oct. 30, 1969
Third Revision ____________________~~~~~~~~-~~-~~ Oct. 24, 1971
Fourth Revision ______-_-__-________~~~~~~~~~~~~~ Oct. 29, 1972
Fifth Revision ______-_-__-________~~~~~~~~~~~~~~ Oct. 22, 1973

Sixth Revision -________-__________~~~~-~~-~~~~~~ Nov. 30, 1974 .

Seventh Revision ____________________~~~~~~~~~~~ -Jan. 7, 1980

.

ii
 . .
TABLE OF CONTENTS Page
: 1. Tools Req~ired-_____~~~~~~~~~~~~~~~~-~~~-______~~~ 2
2. Materials Required___-_-_-~-~~~~_~___~__-________~ 2

3. Heat Treating ________-_--______-_~~~~~~~~~~~~~~~~~ 4

4. Splitting ~~~~~~~~~~~~~~~~~~-~-~-~-~-~-~-~~~~~~--- 5

5
, Staggering ~odes_-~-~~~~~--~~~---~~-~-~----------- 7

6. Spline Preparation ----,-,,,-,,--,-__,L,,,,,,,,,,,, 8

7. Fly Rod Graph ___-___-____________~~~~~~~~-~~~~~~~~ 9

8. Rod Tapers ______________-_____~~~~~~~~~~~~~~~~~~~~ 10
9. Planing Splines _-___--__________--_~~~~~~~~~~~~~~~ 20
10
. Dimensi
onal D
~
erff
en
e
c~ -
~ -
~ -
~~~ --------
~ -
~ -------- 22

11. Glueing Splines --___-_-__________-_-~-~~~~~~~~~~~~ 24

12. Section Preparation _----___-_____-_____----------- 26
13. Rod Assembly --__-_______________-~~-~-~~~~~-~~~~~~ 27

15. Reel Seat ____-________--_____-~~-~~~~~~~~~~~~~-~~~ 32

16. Mounting Ferrules __________-_____---_~~~~~--~~--~~ 33

18. Cork Handle Assembly ______-____-_-____-_---------- 35

19. Cork Handle ~~~p~-~~~~-~~~~~-~~~_~~~~-~--~~~_-___- 36 .
.

20. Syncronizing Fly Rod _______________-__-_~~~~~~~~~~ 37

21. Fly Rod ~~~~~~g~~-~-~~-~-~~~~~-~~~---~-~~~~~~~-~~ 38

22. Guide Spacing Chart ________________---_~~~~~~~-~-~ 39

23. Guide and Rod Winding ________________-___--------- 40
24. Color Preservative-----------------------------~~~ 43

25. Varnish Application _________---------__~~~~~~~~~~~ 43

26. Rod Case Bag ______________------_______r___________ 45
 TOOLS REQUIRED

1. Pair of leather gloves

2. One inch micrometer
3. Center gage
4. 6 inch block plane (Stanley no. 9 l/4)
5. No. 111 Carborundum or JB6 Norton sharpening stone
6. Spline guide block *
7. Mill file
8. Sharp hunting knife

MATERIALS REQUIRED
6' Tonkin cane bamboo
2 tip tops
Snake guides
Stripping guide
1 Set ferrules
1 Reel seat
14 Corks (Manton Portugal)
_
1 Varnish
2 Spools silk thread - Belding Corticelli (Size A - shade 3715 Gold)
1 Champion rod case
1 Rod case cloth bag
1 Color preserver
1 Gun bluing (formula 44140)
1 Steel wool (grade 0000)
2 Sheets Garnet Cabinet Paper (220 grit)
2 Sheets Garnet Cabinet Paper (120 grit)
Pflueger Mending Cement .
Epoxy Glue (not the 5 minute type)
Weldwood Resin Glue

.
4 3 I 2 I 1

57 DEGREES

FIG 1. SHARPING STONE AN0 HOLDER

I
L

4 3 2 1
 HEAT TREATING BAMBOO

Mechanical engineers have used-the process of heat treat-

ment for many years for the purpose of altering material properties.
In the same manner, with the art of bamboo rod making, we
use one of the many processes of heat treating to harden the
bamboo fibers and also to remove any retained moisture from the
cane. This process will give the fly rod a faster recoil action
and make it less resistant to taking a set.
The 6 foot bamboo culm is heated to the critical temperature
by continually passing over a gas torch flame until the cane
turns to a golden brown. Then the cane is removed from the heat
sorce and and allowed to air cool at room temperature.It is during
this period that the cane will smell like roasting nuts. Heat
treating the cane to a dark brown color or charring it runs the
risk of the cane becoming too brittle.
The heat treating is done before any finishing work is
accompolished because during the heat treating process the bamboo
will shrink and distort causing the finished part to be out of
tolerance .

4
_ .

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F
W I DE

V I EW LOOK I NG AT BUT T
OF BAh /l BOO CULM

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-)O ‘ .226(Z .% x& - ,226

SI~J ’60 - x~ = ; 260

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AGG
ER
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bES

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7

.
 SPLINE PREPARATION
(prior to planning)
1. File and sand nodes on the enameled side of spline (do--
not
use plane).
2. Plane nodes flat on pithy side of spline.
3. Straighten splines by applying heat from a camp stove..
4. Plane rough edges of spline square.
Do not use
-- - plane on
- enameled surface.
5. Draw station lines on enameled surface of spline at 3 inch
spacing using black India ink. Start at the butt end of spline.
6. P!ark the planning dimensions at each station using India ink,
begining at the butt end of spline.

/- sT~-I-lorJS
PLAUNN ING.
i3 ‘ 7” 7’
133 13,s 143 I40 1081 l 2Il G1
lI 119 1 1231

ilP sEC7-loti

8
 VlBRATlON RATS ?
FERRU LE :
-- - FLY LINE :

cz(, b a b
A . 14 - . 207 ,21 4 .I 07 --
, 400 , 200 ,206 .
I03
,386 .I 3 3 , 200 .I 00
.3- ?
2 .I 8 6 .I 32 , 096
,358 .I 79 .I 84 .o 9 ‘2
4344 .I 72 .I 7 6 0088
. 333 .I 6 6 .I 6 3 .O 8 4
.3 18 .I 59 .I 60 .o 8 0
, 306 S3
.
l .I 50 bO 7.5
,29 2 .I 4 - 6 . I 42 .c
nf
B2.80 .I 40 .I 3 2 . 0$6
.268 .I 3 4 .I 2+ . 06 , 2
. 256 . I28 .I I4 ,o 5 -7
. 24 6 .I 23 * .I 04 , 052
a2 34 - .I 17 . o 54 , 04 7
. Z 24 .I 12 . a 84 . O f FZ
l 214 .I 0 7 . o 74 ‘. 037
--- ax % - .m1 c- . o 64 *ox2
, 200 .I 00 0
.54 l o G7

PREPARE BAMBOO 'SPL%JES 54 . LONG

 u -
b
Y -
S-J-A w
a:
-
b
m 432 * 221 4 - o - . 7-22 . II I
O- O . 42 6 - 213 .- 3 _ 2.16 . 10s
- 3 . 20 5 -6 . 210 - 105
- 6 _ 198 - 9 . 204 - IO2
- 9 _ 190 s -0 * 199 4 039

I - 0 . 183 - 3 l 190 . ds 5

- 3 . l-76 - 6 . I s2 . 091
- 6 l 33 8 _ 16 9 - 9 . 17+ a 08 7
- 9 . 324 . I62 6- 0 . I.6 4 . 08 2
2- O l 310 l 15s - 3 . 156 l 07 8
- 3 - Z-26 - 149 - 6 . I46 w 07 3

- 6 . 28 4 L 147 - 9 l I38 . 06 3

- 9 . 272 . I3 6 7-O . 12 8 . 064

3-o * 130 .
- 3 . u8 l 05 9
- 3 . 250 . 125 - 6 . IO0 . 054
- 6 -240 l I20 - 3 l 09 8 . 04 9
- 3 . 230 l 115 a- 0 . 088 l 044
G-0 . 22 2 . 111 - 3 w 07 8 . 03 9
- 3 1. 216 . JX3 - 6 . 065 # 03 4

- 6 ’ zio l 105 - 9 . 0!%8 . 029

SPLlNE.5 S-yLONC .

13
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6U
-r-r SECTION TIP
- ST
A cz _
-. b 57
-A 4 b
- 3 434
. .21? 4-o .228 ,I‘4
(3 - 0 4z
.o .2 10 ‘-3 .220 ,I IO
, 0 ‘
- 3 .406 ,203 -6 ,214 JO-7
- 6 .3 sb, ,197 - 9 -2 06 .I 03
- 9 .3 8-o . I90 5 -0 .zoo .I 00
I - 0 .3 6 6 .I 03 - 3 .\92 a(39 6
-3. .3 54 ,I 7-7 -6 .I 0 2 .
09 1
-G .3 4 2 ,\ 7’ - 3 .I 74 .o 07
- 9 .328 .I 64 6-O .I 66 ,083
z- 0 .3 ‘6 ,I ss - 3 .I538 .0-79
-3 ‘ ,304 .I sz - 6 .I 4 8 . 07 4
-CL .29Z .I 4 6 - 9 .I 39 L 069

- 9 ,280 .I 40 7- o .I 30 065
.
3- o ,270 .I 3s - 3 .I 70 ,O 60
- 3 .258 .I 29 - 6 .1 I 0 ,055
- 6 ,248 .I 24 -9 .\ 00 .050
- 9 ,238 ,I 19 8- O l 030 .04s
4- 0 .z2 8 .l ‘4 - 3 .080 ,04 0
- 3 .220 ,i I0 -c .070 ,03 5
- 6 .z I4 I ‘ 07 - 9 ,060 ,030
 BUTT secTlo~u
5-r-A a b S-T- Q b
- 3 s452 ,226 -4 3 ,246 I.23
0 -0 4. 40 -320 - 6 .Z38 .19‘
- 3 .42f3 z. ‘4 - 9 .232 I. 16
- 6 .4 16 .ZOS s-0 .Z 24 ,I I2
- 9 .402 20' - 3 .2ld ,I0 8
I- 0 .3 90 ,195 -6 .2os .I 0 4
- 3 ,376 .I 68 - 9 .zocY .I 00
- 6 ,36 4 .I 02 C
L
- 0 .1 32 ,096
- 3 l 35 2 .I 76 - 3 .I 94 ,092
z- 0 134 0 .I 70 - 6 .1 74 .o 87
- 3 ,328 .I 64 - 3 .t 66 PO 93
- 6 ,316 .I 5s 7- 0 I. s 6 .078
- 9 .306 .I 5 3 - 46
. 3 .‘ ,073
3 - 0 ,234 I47
. -6 .l 3 s .O69
L3 .ze.4 .I 42 - 3 .\ 2 s ,OQ+
-6 .2 7.4 .I 37 s- o .I I 0 ,059
- 9 ,264 .I 32 - 3 .108 .054
4 - 0 l zs4 .I cl - 6 ,096 .O4f3
- 3 ,246 ,I 23 - 9 ,056 ,04 3
-6 .23 B .I 19 3 -0 .o 76 90138
w-9 ,232 l 16 ‘ - 3 .O66 ,033

.j SPLIhlE5 60 ” LOYG

16

;
 5NORT BUTT SECT IO N
FOR MObEL .MO 4’
S
-VP 5ECTm~

- 3 930
. . ‘9 5
o- o l 37 6 I. ss
- 3 0364 ,I 8 2
- 6 ,35 2 \. 76
- 9 . 34 0 l170
I- 0 a320 , 164
- 3 \,3
b *I 5 8
- 6 0306 I.53
- 9 92+. J47
z- 0 ,284 i+ . 2
- 3 ,274 I. 37
- 6 ,264 ,I 3 2
- 9 254
. .I 27 .

3- O . 246 I.23
- 3 .238 _ I\ 9

- 6 .23 2 . II
6

PREPARE 84MBoO 5PLlhE.s 4s ”O

LWG

17
 WNDA LBROOK
HO -( FL , QOC
ObFL
/\E NO . 525

BUTT ION SECT

STA a b
- 3 a472 2
.36
o- o ,46 0 .
230
- 3 .44s .
22 4
-6 .436 .
218
-3 .424 ,212 -6 .2?$- ,I ’ 7
I- O ,4- 10 ,205 - 9 .226 .I I 3
- 3 ,33 8 .I 99 6- o ,218 .I 09
-6 .386 -1 9 3 - 3 .2IO .I 05
- 9 .376 .I 80 - 6 ,20 0 .I 00
2 - 0 .364- .I 82 -3 .I 32 .036
- 3 .?a 5 2 .I 7 6 7 -0 .\ 82 ,091
- 6 .3 4 0 l 70l- - 3 .I 7 2 ,086
- 9 .330 .I 65 - 6 .I 62 .o 81
3- o .3 20 .I 60 - 9 52.I 0076
-3 ,310 ,I 55 8 - 0 .\ 42 .071
-6 ~ ,298 ,I43 - 3 .I 3 2 l 066
-3 .200 ,I 4 4 - 6 .I 22 ,061
I
4 -0 .280 .I 40 -3 .I 12. .056
-3 .272 .I 36 3 - 0 ,102 .OSl
-6 .264 ,I 32 - 3 .o 90 .045
-9 ,256 .t 28 -G .o 80 .0+0
s- 0 .2 s 0 .I 25 -9 1 .070 1 .0335
Each sl:line is to be plcnrled into an e.luelcteral triangle, t-here eech
6nSle is 60°, and to the finished dimensions merked on the spline.

To plane the spline to the finished dimension follow the steps out-
lin!d $10~:
. rlece the strsiehtened .spline in tge guidp block with en&-eled
'surface ageinst one side of the 60 groove (Fig. 1).

FlC,URE 1 FIGURE 2 FIGURE 3 *

2. T&e ten (10) strokes with the plane parallel to the top of
the guide blo:k. Always plane 3 to 4 stations at a time with each
plane stroke.
3. Rotate the spline in guide block with'the enameled surface -
against the other side of the groove. . Then take ten (10) strokes with
the plene perallel to the top of the guide biock. (Fig. 2) The spline
will then have the shape shown in Fig. 3.
4. Repeat steps 2 &'3 until the'spline is in the shape of an
e;uelateral triangle.
j. IIike'each station andeobtain the difference between the.reading
and the actuel dimension. For example if you mike ;2j8 on one face at
station .Zo&, then with a pencil mark 59 on that face. Gn the other._
side at station .20@ if you mike .26O, then mark 52. These dimensions
ere thousandths of an inch over the finished dimension.
 : _. .. , .

I. .
6.
Repeat step 5 at each station for &he entire length of the"’: ‘
. ‘. _ ’:
spline.
7. Khen 'plening the spline down to rinish dimension It's best to
have a shaving .002 in thickness. It will be easier to keep treck of
material removed by multiplying the shaving thickness times the number
of strokes taken. % *_ I

.2d _ _. FIGURE 5
X08

t\ 8. Plans the spline down to 20 thousandths over dimension. In the

example, start at station .195 and take two strokes on each face and
without miking, this dimension should be down to 36. Then take three
strokes on each face covering station .201 and .195 which will make
stations .208, ,201 and .19j 32 thousandths over dimension. Now these
three stations can be planed down to 20 thousnadths over size. Repeat
this procedure for the entire length of the spline. Plane the entire
spline to 20thousandths over size dimension.
. 9. Check the apex angle of the spline only with the center gage (Fig.6)

l
=l
GURE G FIGURE 7
If e gep appears between the spline and center gage (Fig. 71, you
are tilting your plane away from the enameled surface. Plane parallel _
to the top of the block.
10. Plane the entire length of spline down to 10 thousandths over
dimension.
11. Now plane the spline down to the finished dimension with a'
tolerance oft.001. Check the angle of the spline with the Center Gage
;','hen planing splir.os to dirilension one problem alvrays arises, t1Aat
is WIDlmensional Difference". This is cmsed by tilting the plene too
much to the left or to the right when planing. The dimensional diff-
erence is fcund by su'btrcctinc the miked values over finished diruen-
sion at any one station.

CUYE
F’ J

.ZOl
l 208
The dimensional difference tit stetion 208 is .006, at 201 it's .bO8
and at station 195 it's .COV. There will alcays be some dimensional
difference when planing splines. Even after becoming proficient at
planing,you will al-bveys be correctirq for dimensional difference. The
tine to start correctin& dil::ensionel difference is immediately, when
your.60, 59, or 40 thousendths over diihension, not when you are 10 over.
To correct for dimensional difference follow the steps outlined below:
1. Mice all the stations and mark the number of thousendths over
dimension on the ftice of the spline (?ig. 1).
2. Take the srline and piace the smallest dimension UP (40, 42 6; 46)
pnd note which side the ener:leled surfsce is on (LG'T in fig. 1). Eow
place the .spline in the guide block with the tmzllest dimension UP (Fid 2).

FIGURE 2

3. To correct for dimensional difference tilt the plane toward the

enemled surface, which is LXFT (Pig. 2).
4. Take - three strokes with the plane ($is. 3). PLAhlNG’
SURFAC E
PLAhIlti)G SJRFACE\I_
- - . ’ z
- - - -

I L--- a

FIGURE 3 FL
URE , 4

5. :?otrte the spllne in the guide block so dimensions 46, 30 8: 55

ere up ("12. 5).
 6.Take three strokes with the plane still tilted to the LEFT
(Fig. 4).
7. Mike the stations again and the dimensional difference will be
getting less.

8. 1f.i.n step 2 the enameled surface was on the RIGHT, then to

correct for dimensional difference tilt the plane to the RIGHT and
take three strokes. Rotate the spline in the guide block and take 3
strokes on. other surface, with the plane still tilted to the RIGHT.
9. By following the above procedure to correct for dimensional
difference you will be planing the spline into the shape shown in
Figure b(b).
’ A i

BEFOR E PLANING AFTER PLANING

-FIGURE 6 (a ) FIGURE 6 (b)
Figure 6(b) shows why it is SO important to start correcting for
dimensional difference immediately. Although the first few strokes with
the plane will correct dimensional difference it results in a missing
corner. This is why it is essential to start correcting dimensional
difference when you are ,040 over dimension. Sufficient material is
available at this point to plane out that missing corner (Fig. 7).

-FIGUR E 7
 GLUEING SPLINES

Gluet
Resin - Cascophen RS- 240 MD
Catalyst - FM - 124 - D
(Keep'refrigerated to increase shelf life).
Sourcet The Borden Chemical Co.
Can now obtain this glue from Ernst Hardware, Seatle, Wa.
.
Mixing Gluet
(1) Five parts of resin to one part catalyst by weight.
Example - 100 grams resin
20 grams catalyst (hardener)
(2) Filter the catalyst(powder) through a pair of panty hose
to remove large grannules.
Pot life of gluet
The manufacturer says 3 l/2 hours. However for best results
the pot life should not exceed one hour.
Optional gluet
URAC 185
Obtain from fiberlay Inc. Seattle, Wa.

PROCEEDURE:
1. Bring splines to 70° F slowly and hold at this temperature
for 24 hours before applying glue.
L.
_ Wrap adhesive tape around splines in 2 places, approximately
3in. and 18 in. up from the large end of the butt and
tip sections.
3. Cut the tape carefully,along one spline with a sharp knife
and lay splines out flat on a board.
4. Apply glue to splines with a stiff one inch paint brush.
Cut bristles approximately l/2 inch long.
5. Brush on one thin coat of glue, covering all surfaces
thoroughly.

6. Apply second coat of glue, covering all areas thoroughly.

7. Bring splines together and remove both strips of adhesive
tape from the tip sections and the tape 18 in. up from
the end on the butt section.

8. Spiral rod winding thread the full length of section

to keep splines in position on the tip section only.
9. Immediately apply pressure to section with the wraping ~;A
machine.
 - - ‘- ‘_I-- -. ___
__
_ __
. _ ._._ -. - _
c . _ . d*-.-.
- s. w
___ ., ._ . __
. c
I. ------

Glueing Splines (Contd.)

10. Check section for straightness before placing section in
the hot box.
11. Place sections in theohot box. Apply heat and bring
temperature up to 130 f and hold at this temperature for
4 hours minimum.
12. Remove the heat source and allow the tempgrature in the
hot box to reduce to room temperature (70°F).
13. Kegp the sections in the hot box for 8 hours minimum at
70 f. The longer the cure period the better.
14. Wait one week before removing the string from the sections.

3 A_ - \
 SECTION PREPARATION
(After gluing)

1. Remove string from sections.

2. Scrape sections with a stiff,sharp knife. Apply enough
pressure to prevent knife from chattering. Remove the
cloudy enameled surface from the sections.
3. Very lightly draw the knife over each corner of the section
only once.
4. Check sections at each node for high spots. If high spots
are present, file flat.
5. Sand each side of.the section with 220 grit Garnet paper.
The number of strokes taken with the grit paper must be
done the same number of times on each side of section,
20 strokes on the butt section and 10 on the tip section.

6. Locate the trim station. It may be necessary to relocate

the trim station on the section(i.e. instead of 3 in. from
end on the #415 it may be 2 in. from the end). The trim
station must be located to the best position so that very
little sanding is done to bring the sections within tolerance.
7. Sand the section down to dimensions specified within + 0.001.
8. Rub sections with grade 0000 steel wool. Rub the section
approximately 20 strokes. Cautiont On the tip section draw
the upper half through the steel wool with the tip pointed
away. Rubbing back and forth may cause tip breakage should
the rod tip accidently catch in the steel wool.
'9. Finish the section by rubbing and polishing with bamboo
shavings. Bring section to a high luster. Excerise the
same caution in polishing the tip section as described
in step 8.
.

26
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 i

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 END OF BAMBOO

EhlD OF
B
AWRoo 3k t DIA
AL
UM RIVE T

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1
 ROD ASSEMBLY
(Short Butt d Tip Section)
The short butt section is for use with the tip section of the 9 foot
rod. The assembled short butt and tip section make a 7 foot 9 inch
dry fly rod.

2 9
 I.:WIZ'II\TG FZ_RRULES

1. Trim butt section at ferrule end-as shown on assembly sheet.

2. File trimled end of butt section.
3. Position the ferrule next to the butt section as it would appear
in the assembled condition. Mark the serrated end of ferrule
on bamboo with a pencil. Place a secondmark on the bamboo to
correspond with the end of the serrated slot. (see Fig. 1).
4. Try fitting ferrule on bamboo before filing the hexagon corners.
5. Zlake one pass of a mill file on each corner of hexagon approx-
imately half the distance to the first pencil mark. Count as
you file the corners, 1 on first corner, 2 on second corner, 3
on third, etc. Always count to assure equal material removal
on corners.
6. After first pass around the corners try fitting I"errule on butt
section. Repeat step five until ferrule just starts to slide
onto bamboo. .

7. Now start filing the other half of bamboo to the first pencil
mark, and count as you file each corner. File down this half to
the same diameter as the first half.
8
. F/hen both halves are the same diameter, file both halves simult-
aniously in one smooth stroke. Count each corner. Continue until
ferrule will slide to within $I1 of first pencil mark.
9. File a taper from first pencil mark to within l/8" of second
pencil mark, without sharp knicks or steps.
10. Apply one coat of EPoW. adhesive to the filed section of bamboo
and to the inside of ferrule. Do not use the 5 minute epoxy because
it is not water resistant.
11. Slide ferrule onto bamboo as far as possible by hand.
. 12. Heat ferrule with an alcohol lamp.
13. Once ferrule is hot to the touch, press the ferrule on up to
the second pencil mark and hold until ferrule starts to cool.
14. Installation of ferrule on tip section is the same as on the
butt section except that when the first half of bamboo is filed
the ferrule will start to slide all the way on; so none or very
little bamboo removal will be required on the second half. Be
careful not to take too heavy a stroke with file on tip section.
15. Proceed with steps 10 through 13.
END OF 5ERsArEb SLO T
. k-
SERRATED Eh(D ’ OF FERRULE
c 3 3
FIGURE. I
 I.'OUIX'I~~G REEL SEAT

1. Install wood insert and plug into reel seat.

2. Position reel seat next to butt section to agree with overall
length. &ark the forward end of reel seat on the bamboo.
3. Measure 2" back from pencil mark (away from ferrule) and trim
bamboo here.
4. Drill j/81? diameter hole in wood insert.
5. File dovin the bamboo (where reel seat attaches) to a slightly
larger dimeter than the j/g11 hole in insert. Filing the bamboo
is done in the same manner as mounting of ferrules.
6. Apply one coat of EPOXY adhesive to the O.D. of wood insert
and I.D. of reel seat.
7. Install wood insert into reel seat.
8. Apply one coat of Epoxy adhesive to the filed section of bamboo
and I.D. of wood insert.
9.Install the reel seat on the butt section up to the pencil mark.
This is a press fit and will require an installation tool.
10. Before. installing reel seat hood,check the butt section for the
correct side to mount guides.
(See PUye 37)
11. Apply one coat of Epoxy adhesive to I.D. of reel seat and hood
and O.D. of reel seat where hood attaches.

12. Install reel seat hood and position it so the reel socket of
the hood is on the same side of hexagon that the guides will
be mounted.
13.Drill #40 diameter hole through hood, reel seat and bamboo.
.
14. Countersink 100' each side of hole.
15. Install 3/32 diameter aluminum rivet and peen over to fill count-
ersink. File the rivet ends smooth with surface of hood.
16. Install reel seat plug with a light press fit. If too loose
awedge .649 diameter slightly,larger to obtain an interfer-
ence fit. Caution, Install the reel seat plug after the cork
handle has been shaped to size.

3 4
 1. 14 cork rings (3/g', I.D. x lktv O.D. x 3') long) are re@red to
make the handle.
2. Double wrap string around the O.D. of cork ring and tie off.
3. .File I.D. of cork ring with a rat tail file slightly smaller
than O.D. of' reel seat hood. File a small notch in I.D. of cork
for the hood reel socket.
4. Coat I.D. of cork ring with Epoxy adhesive.

5. Apply one coat of Epoxy adhesive to hood on reel seat.

6. Slide first cork ring (with string attached) over butt section
and press onto hood l/l611 beyond end of hood.

7. Allow the first cork to set on reel seat one day before install-
ing remaining corks.
8. The remaining 13 cork rings are installed onto the butt section
with Weldwood Resin glue.
9. PresSthe cork rings onto the bamboo section (do not file I.D.
of cork rings) and apply a light coat of glue to the faying
surfaces.
10. Press each cork ring firmly against the previously installed
cork ring. Glue will extrude from the faying surfaces.
11. When. all cork rings are installed, wipe excess glue from cork
handle and allow to dry for one day.
12. Turn handle with a drill motor or lathe. Using sand paper,
shape the handle to the approximate size shown on page 36.
Modify to suit your own hand grip.

13. Do not apply an9 finish or protective coating to the cork handle.

3 5
 HANDLE
CORK SHAPE

0
0.

ii .
I. 40
z

IT
0
I-

.0 .
ln
.

-/L- 36
 SYNCRONIZING THE FLY ROD
Syncronizing the fly rod is a procedure we use to determine
which hexagonal flat is used for placement of the guides and reel
seat hood.
This is very important because during the casting stroke the
fly rod must flex within a flat plane, or a straight line and not
bend in a curved arc. The faster the rod is moved and the harder
it is stopped, the more the tip bends over the resistance of the
butt, a movement that imparts tremendous force and speed to the
fly line. This extra flip at the end of each casting motion is
the method used by expert casters to form a fast narrow line
loop. Therefore, to benefit from this rod tip flip, the rod tip
should flex within a flat plane to maintain control of the fly
line.
Due to planning, glueing and even the mass of the bamboo itself,
one side of a rod will be stiffer than the other sides which effects
the natural vibrating period of the rod section. The natural period
being where the rod tip travels in a straight line up and down when
it is vibrated. To find this flat proceed as followsr
1. Place the butt end of the rod section on a table with the
tip end extending beyond the table.
2. Bend the tip end of rod down with thumb and index finger (fig 1).
Release, and watch the tip end vibrate in an up and down
direction.
3. If the tip travels in an elliptical arc (Fig.2) or at an angle
off the horizontal while it is vibrating, rotate the rod to
the next flat and repeat the procedure.
4. Vibrate the rod on each of the six flat s-ides until you find
the side where the tip end will travel in a straight up and
down motion (Fig. 3). One side will generally produce a
straight up and down vibrating motion.,
5. Once having located this flat, mark its surface with a pencil.
This is the side which-is aGainst the table and the one where
you will place the guides.

3 7
;
 P ERFECTI O N TIP COvwAkJY
PCF - FLY R013 roe‘ WCG - CASr’
NG
SSGP - SNAKE GUIDE S BOAT Roh GUIDE

38 ;
GWDE SPACING CHAR T

3 3
;
 PLACEMENT OF TIP HOP‘

-------
3

9’ RO D
(I\ GUIDES )

.
 GUIDE li, X!D~,~Ii:1',iIIG

!:I.T:lliI;.L: 2 Spools of silk thread, Lelding-Corticelli

Size A - shade 3715 Cold

GUIDE '\'IKDIIL‘G:

1. File burrs off foot of each guide to keep from cutting thread.

2. !'.'ind thread on rod the width of the flat of the hex. This
dimension will become less when guides are Wrapped on closer
toward the tip top. The minimum rt~1* dimension shall be l/8 inch.
3. Space each turn so they touch without over-lapping.
4. Xhen the width of the winding is complete make three turns
on foot of guide l/l 6 inch from end. Then wiggle guide and
at the same time pull until foot of guide just disappears
under winding thread.

PULL TH KO UGG laOFJi

5. ;Jind thread on foot of guide up to point where thread comes to

lleyell of the guide. Nrap back over the first layer 15 turns
making sure the last 6 to 9 turns are over the"pul1 through
- loop".

6. Pass end of winding thread through loop and pull thread under
previous wraps.
7. Pull end of winding thread tight and cut as close as possible
to windings with sissors.
8. Complete windings on all guides.

40
 9. Kind thread on rod 3/s inch from cork handle and wrap up to
cork with the thread spacing very tight. Zrap back over the
entire first leyer making sure the last 6 to 9 turns are over
the "pull through loop".
10. Pass end of winding thread through loop, pull thread through
and trim end with sissors like the steps in 6 and 7.

11. Wind thread on rod 4l/ inch from ferrule and wrap up to
ferrule, with the thread spacing very tight. Vl'rap back over
the entire first layer and then back over the second layer
up unto the ferrule to the first step or l/8 inch beyond the
slots. V/rap back over the first layer on the ferrule stopping
at the end of the ferrule. Again making sure the last 6 to 9
turns are over the "pull through loop?

12. Repeat step TO.

13. Virap thread at the tip top using procedure of step 11.
14. After completing all wrappings singe the fuzz off the thread
windings by rapidly passing over an alcohol lamp flame. This
is done prior to application of color preservative.
DECORKTIVE ;'!RAP: .

15. A decorative wrap may be added to each rod winding by using

size A black silk thread.

16. V/hen starting each wrap on guides, ferrules, tip top and at
handle wrap over a 10 inch piece of bleck silk thread with the gold
thread. Finnish wrapping the gold wind ings on all rod
mountings.

icaLAc SILK
TMRREAD

41
 17. Place a "pull through loop 0 over the gold thread and wrap
three turns over the loop and pass end of black thread through
loop and pull thread under the three previous wraps.
18. Do not trim end of black thread at this time.
19. Complete the decorative wrap on all guides, ferrules, handle
and at the tip top. ’

20 .Pull end of black winding thread tight and cut as close as

possible to windings with sissors.

. . . 21. Singe windings per step 14.

22 .Immediately apply a coat of Color preservative to all windings.

42 ,
;._
 ROD \'II;DIKG COLOR ~RESERVXTIV-E

Preparation:
Xix,equal parts, by volume, of amyl acetate (banana oil) and
fl~~~b-fe collodion. 1 oz. to 1 OZ. Obtain from local pharmacist.
Application:
After completing rod wrapping apply color preservative to silk
thread with a clean brush. After each application, allow the
thread to dry and return to its natural color before the next
coat is applied. A total of three coats should be ap lied. The
solvent used for brush cleaning is lacquer thinner. R ake sure
that all coats are flow coats.

\.'
VjRNISH APPLICATION
LIaterial:
Ultra-Marine Spar Varnish
Obtained from Katson Paint Products Inc., Seattle, Kash.
Application:
'I
I* Apply one coat of varnish to the rod wrapings with a l/8" to
1/4l' hair paint brush.
2. Allow varnish to dry 24.hours and then apply a second coat
on-the rod wrapings only.
3. Allow varnish to dry 24 hours and then apply a third coat
on the rod wrapings only.
4. To varnish the entire rod and obtain a mirror finish re-
quires the use of a lint free room. This room
is the bathroom. It is best to varnish the rod at night
when everyone has gone to bed. This will help keep the bath-
room as lint free as possible, by not having the door
opened too many times.
5. Turn the hot water on in the shower or tub for a few minutes
to get the room full of steam. This procedure will settle
all lint and dust particles in the room.
6. V&en applying varnish to the entire rod it must be done
with the fingers, not a brush.
7. Remove cap of varnish bottle and put index finger over the
opening and invert the bottle to get varnish on finger. D O
not put the bottle down, but hold in the palm of hand in
an upright position. This saves time by not having to pick
bottle up and setting down.
8. Apply varnish to sections of the rod (between guides) going
over each face of the hexagon.
9. Do not apply varnish too thin and not so thick that it runs.
As you run your,finger over the hex faces, it should glide
smoothly and not drag.
10; LIake sure that varnish gets under each guide and apply
varnish to the blued surfaces of ferrules.
11. ';/hen one rod section is complete, stand it in the corner
of'bathroom.
12. Apply varnish to next rod section and when complete stand
it in corner.
4 .3.
 ‘,
Varnish Application Contd.
13. Turn first section upside down. This procedure helps to
L.

prevent runs in the varnish.

Apply varnish to third section and stand it in corner.
i;: Turn first and second sections upside down.
16. Continue turning rod sections upside down every S-10 minutes
for 1 hour minimum. This is enough time for the varnish to
set.
17. Leave rod sections in the bathroom until morning and then
they may be put in another room. -Do not- grasp the varnished
portion of the rod too firmly because finger print impressions
can be left in the varnish. One week is a good length of
time for the varnish to become hard.

DIP VARNISHING
(Optional Method) --‘
.

Varnisht Varmor Clear finish Gloss Interior/Exterior

Source: Pratt & Lambert Inc.
This is a synthetic, plastic-base polyurthane varnish which will
give the rod a life-long indestructible finish. It dries very hard
and very quickly.
Four coats of varnish are applied at 8 hour intervals.

4 4
ROD CASE BAG

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