06/07/09

Rod Making – Major Steps Introduction Getting Started – Tapers, Construction & Other Design Considerations Initial Steps – Working with Raw Bamboo Flaming, Splitting and More Node Work Roughing, Heat Treat and Finish Planing Gluing Final Assembly and Hardware Guides, Wrapping and Finishing Bags, Tubes and other final items 06/07/09

Introduction

Getting Started – Tapers, Construction & Other Design Considerations

Initial Steps – Working with Raw Bamboo

Flaming, Splitting and More Node Work

Roughing, Heat Treat and Finish Planing

Gluing

Final Assembly and Hardware

Guides, Wrapping and Finishing

Bags, Tubes and other final items

All you ever wanted to Know . . . Started fishing in 1959 (age 8) Started Fly Fishing in 1969 (older) Started making bamboo rods in 1997 (older still) Started Brack Hill Tackle in 1998 06/07/09 Celebrated 10th Anniversary in 2008 (very old)

Started fishing in 1959 (age 8)

Started Fly Fishing in 1969 (older)

Started making bamboo rods in 1997 (older still)

Started Brack Hill Tackle in 1998

Celebrated 10th Anniversary in 2008 (very old)

Decisions, Decisions, Decisions . . . 06/07/09 Squares, Pentas and Hexes 1,2,3 or More Pieces What’s up with Tapers?

Squares, Pentas and Hexes

1,2,3 or More Pieces

What’s up with Tapers?

Selecting the Taper is the most critical step in the process Hundreds of “Classic” tapers from books, Web and measured rods Taper stress calculations illustrate rod flex attributes Taper design software allows modification of known rod to other lengths, weight, etc. Decisions Continued 06/07/09

Selecting the Taper is the most critical step in the process

Hundreds of “Classic” tapers from books, Web and measured rods

Taper stress calculations illustrate rod flex attributes

Taper design software allows modification of known rod to other lengths, weight, etc.

Decisions Continued 06/07/09

Intial Steps – Working Bamboo 06/07/09

Intial Steps (Continued) 06/07/09 Saw 12’ culm into 2 halves Top used for Tips, bottom for Butts and Mids Remove nodes at each end when possible Split each half into quarters Dress nodes prior to Flaming Nodeless – No thanks!

Saw 12’ culm into 2 halves

Top used for Tips, bottom for Butts and Mids

Remove nodes at each end when possible

Split each half into quarters

Dress nodes prior to Flaming

Nodeless – No thanks!

Intial Steps (Continued) 06/07/09 Node and Diaphragm

Initial node prep – The outer surface is filed flush to the adjacent Bamboo enamel. When all nodes have been filed smooth – Bamboo is ready for flaming. Intial Steps (Continued) 06/07/09

Initial node prep – The outer surface is filed flush to the adjacent Bamboo enamel.

When all nodes have been filed smooth – Bamboo is ready for flaming.

Flaming, Splitting, More Node Work 06/07/09 Flaming enamel surface of the Bamboo Culm

Flaming, Splitting & More (Cont.) 06/07/09 Begin by splitting each half culm into thirds. Pressure against splitting blade will guide split down the length of Bamboo Continue splitting each 1/3 in half.

Begin by splitting each half culm into thirds.

Pressure against splitting blade will guide split down the length of Bamboo

Continue splitting each 1/3 in half.

Flaming, Splitting & More (Cont.) 06/07/09 Splitting Sequence Split each culm into 2 halves Split each half into thirds Continue splitting each 1/3 in four final strips Should result in 24 strips from bottom half (for butt and mid) and 24 from top (for tips)

Splitting Sequence

Split each culm into 2 halves

Split each half into thirds

Continue splitting each 1/3 in four final strips

Should result in 24 strips from bottom half (for butt and mid) and 24 from top (for tips)

Flaming, Splitting & More (Cont.) 06/07/09 Strip 1 Strip 2 Strip 3 Strip 4 Strip 5 Strip 6 Node Stagger Illustration Strip 1 Strip 2 Strip 3 Strip 4 Strip 5 Strip 6

After stagger is arranged, sections are trimmed to rough length. Nodes are now “pressed” to align power fibers with adjacent fibers in the strip. Flaming, Splitting & More (Cont.) 06/07/09

After stagger is arranged, sections are trimmed to rough length.

Nodes are now “pressed” to align power fibers with adjacent fibers in the strip.

Rough planing (or milling) processes strips into 60° equilateral triangular sections Two forms are required Roughing also reduces the sections to a consistent size – ready to finish After roughing, strips are bound in sequence and heat treated Roughing, Heat Treat and Finish Planing 06/07/09

Rough planing (or milling) processes strips into 60° equilateral triangular sections

Two forms are required

Roughing also reduces the sections to a consistent size – ready to finish

After roughing, strips are bound in sequence and heat treated

Roughing, Heat Treat and Finish (continued) 06/07/09 End view of 1 st Rough Form

Roughing, Heat Treat and Finish (continued) 06/07/09 End view of first rough form used to cut one 30° angle with Stanley 9 1/2 block plane End view of second rough form used to complete triangle cross section with Record Low-Angle block plane

End view of first rough form used to cut one 30° angle with Stanley 9 1/2 block plane

End view of second rough form used to complete triangle cross section with Record Low-Angle block plane

06/07/09 Roughing, Heat Treat and Finish (continued)

Roughing, Heat Treat and Finish (continued) 06/07/09

Roughing, Heat Treat and Finish (continued) 06/07/09

Roughing, Heat Treat and Finish (continued) 06/07/09

Roughing, Heat Treat and Finish (continued) 06/07/09 Final test strips with “New” rough mill

After heat treat cycle, adjustable steel forms are set to required taper dimensions Finish plane and scraper used to cut strips to final size Block plane is used to remove material to within .020” of the form surface Scraper, set to remove .001” chip is used to finish strip flush with form surface Roughing, Heat Treat and Finish (continued) 06/07/09

After heat treat cycle, adjustable steel forms are set to required taper dimensions

Finish plane and scraper used to cut strips to final size

Block plane is used to remove material to within .020” of the form surface

Scraper, set to remove .001” chip is used to finish strip flush with form surface

Roughing, Heat Treat and Finish (continued) 06/07/09 Low-Angle block plane to begin finish planing

Roughing, Heat Treat and Finish (continued) 06/07/09 Scraper to complete finish planing

Block plane vs. Scraper shavings Finished tip strip – typically .035” or thinner than a slightly worn Roosevelt dime Roughing, Heat Treat and Finish (continued) 06/07/09

Block plane vs. Scraper shavings

Finished tip strip – typically .035” or thinner than a slightly worn Roosevelt dime

The Glue Job 06/07/09 All 3 sections cleaned, taped and ready to glue

The Glue Job After all strips are finished planed, they are cleaned, arranged in the proper sequence and taped together before gluing Nyatex Epoxy is used – applied liberally (not by Hillary) worked into the bamboo surfaces Strips are bound again, straightened and allowed to cure for 24 hours Final heat treat sets epoxy permanently! 06/07/09

After all strips are finished planed, they are cleaned, arranged in the proper sequence and taped together before gluing

Nyatex Epoxy is used – applied liberally (not by Hillary) worked into the bamboo surfaces

Strips are bound again, straightened and allowed to cure for 24 hours

Final heat treat sets epoxy permanently!

The Glue Job 06/07/09

The Glue Job 06/07/09

Final Assembly & Hardware Several steps now required to assemble rod hardware After the epoxy is heat cured, the binding thread is removed and the sections are block sanded to remove glue and enamel surface The ferrules are prepped and rod sections dressed to accept ferrules The reel seat and grip area is cleaned and prepped 06/07/09

Several steps now required to assemble rod hardware

After the epoxy is heat cured, the binding thread is removed and the sections are block sanded to remove glue and enamel surface

The ferrules are prepped and rod sections dressed to accept ferrules

The reel seat and grip area is cleaned and prepped

Final Assembly & Hardware 06/07/09 Before & after block sanding & tung oil

Final Assembly & Hardware 06/07/09 Ferrules prepped and sections ready for epoxy

Final Assembly & Hardware 06/07/09

Final Assembly & Hardware 06/07/09 Walnut Burl slab used for turning reel seat fillers.

Walnut Burl slab used for turning reel seat fillers.

Final Assembly & Hardware 06/07/09 Finished Birds-Eye, Madrone & Maple Burl fillers

Final Assembly & Hardware 06/07/09

Guides, Wrapping and Varnish Now very close to completing the rod, it’s time to wrap & finish guides and varnish the completed fly rod Silk thread used for a smooth, fine finish Hard Chrome snake guides in Bright or Bronze Mildrum Carballoy or Agate Strippers Epifane spar varnish in a dip tube for final high gloss finish 06/07/09

Now very close to completing the rod, it’s time to wrap & finish guides and varnish the completed fly rod

Silk thread used for a smooth, fine finish

Hard Chrome snake guides in Bright or Bronze

Mildrum Carballoy or Agate Strippers

Epifane spar varnish in a dip tube for final high gloss finish

Guides , Wrapping and Varnish 06/07/09

Guides, Wrapping and Varnish 06/07/09 Steps for wrapping guides Wrap over tag to trap thread Wrap in pull loop – allow for 10-12 final wraps Thread tag through loop Pull loop Trim tag end Light burnish – Done!

Guides, Wrapping and Varnish 06/07/09 Signature wrap is used to finish front of grip – open loops represent line weight Finish wrap to secure ferrule tabs

Signature wrap is used to finish front of grip – open loops represent line weight

Finish wrap to secure ferrule tabs

Guides, Wrapping and Varnish 06/07/09 Classic colors of Pearsall’s Gossamer Silk Thread

Guides, Wrapping and Varnish 06/07/09 Variety of Golden Witch Agate & Jasper Strippers

Guides, Wrapping and Varnish 06/07/09 Varnish dip tank & dust proof enclosure Low R.P.M. motor extracts rod from tube at 2 inch/minute Rod is paused at guides to prevent sagging

Varnish dip tank & dust proof enclosure

Low R.P.M. motor extracts rod from tube at 2 inch/minute

Rod is paused at guides to prevent sagging

Guides, Wrapping and Varnish 06/07/09

Bags, Tubes and Final Items 06/07/09 Soft cotton rod bag hand sewn for each rod

Bags, Tubes and Final Items 06/07/09

Bags, Tubes and Final Items 06/07/09 Powder coated tube, vent seal cap & fleece sock

The End 06/07/09 If I used a Bamboo Rod, I’d be holding the big Rainbow !