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Rod Making Presentation


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A brief slide show of the process used in the Brack Hill Tackle rod shop

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Rod Making Presentation

  1. 1. 06/07/09
  2. 2. Rod Making – Major Steps <ul><li>Introduction </li></ul><ul><li>Getting Started – Tapers, Construction & Other Design Considerations </li></ul><ul><li>Initial Steps – Working with Raw Bamboo </li></ul><ul><li>Flaming, Splitting and More Node Work </li></ul><ul><li>Roughing, Heat Treat and Finish Planing </li></ul><ul><li>Gluing </li></ul><ul><li>Final Assembly and Hardware </li></ul><ul><li>Guides, Wrapping and Finishing </li></ul><ul><li>Bags, Tubes and other final items </li></ul>06/07/09
  3. 3. All you ever wanted to Know . . . <ul><li>Started fishing in 1959 (age 8) </li></ul><ul><li>Started Fly Fishing in 1969 (older) </li></ul><ul><li>Started making bamboo rods in 1997 (older still) </li></ul><ul><li>Started Brack Hill Tackle in 1998 </li></ul>06/07/09 <ul><li>Celebrated 10th Anniversary in 2008 (very old) </li></ul>
  4. 4. Decisions, Decisions, Decisions . . . 06/07/09 <ul><li>Squares, Pentas and Hexes </li></ul><ul><li>1,2,3 or More Pieces </li></ul><ul><li>What’s up with Tapers? </li></ul>
  5. 5. <ul><li>Selecting the Taper is the most critical step in the process </li></ul><ul><li>Hundreds of “Classic” tapers from books, Web and measured rods </li></ul><ul><li>Taper stress calculations illustrate rod flex attributes </li></ul><ul><li>Taper design software allows modification of known rod to other lengths, weight, etc. </li></ul>Decisions Continued 06/07/09
  6. 6. Decisions Continued 06/07/09
  7. 7. Intial Steps – Working Bamboo 06/07/09
  8. 8. Intial Steps (Continued) 06/07/09 <ul><li>Saw 12’ culm into 2 halves </li></ul><ul><li>Top used for Tips, bottom for Butts and Mids </li></ul><ul><li>Remove nodes at each end when possible </li></ul><ul><li>Split each half into quarters </li></ul><ul><li>Dress nodes prior to Flaming </li></ul><ul><li>Nodeless – No thanks! </li></ul>
  9. 9. Intial Steps (Continued) 06/07/09 Node and Diaphragm
  10. 10. <ul><li>Initial node prep – The outer surface is filed flush to the adjacent Bamboo enamel. </li></ul><ul><li>When all nodes have been filed smooth – Bamboo is ready for flaming. </li></ul>Intial Steps (Continued) 06/07/09
  11. 11. Flaming, Splitting, More Node Work 06/07/09 Flaming enamel surface of the Bamboo Culm
  12. 12. Flaming, Splitting & More (Cont.) 06/07/09 <ul><li>Begin by splitting each half culm into thirds. </li></ul><ul><li>Pressure against splitting blade will guide split down the length of Bamboo </li></ul><ul><li>Continue splitting each 1/3 in half. </li></ul>
  13. 13. Flaming, Splitting & More (Cont.) 06/07/09 <ul><li>Splitting Sequence </li></ul><ul><li>Split each culm into 2 halves </li></ul><ul><li>Split each half into thirds </li></ul><ul><li>Continue splitting each 1/3 in four final strips </li></ul><ul><li>Should result in 24 strips from bottom half (for butt and mid) and 24 from top (for tips) </li></ul>
  14. 14. 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
  15. 15. <ul><li>After stagger is arranged, sections are trimmed to rough length. </li></ul><ul><li>Nodes are now “pressed” to align power fibers with adjacent fibers in the strip. </li></ul>Flaming, Splitting & More (Cont.) 06/07/09
  16. 16. <ul><li>Rough planing (or milling) processes strips into 60° equilateral triangular sections </li></ul><ul><li>Two forms are required </li></ul><ul><li>Roughing also reduces the sections to a consistent size – ready to finish </li></ul><ul><li>After roughing, strips are bound in sequence and heat treated </li></ul>Roughing, Heat Treat and Finish Planing 06/07/09
  17. 17. Roughing, Heat Treat and Finish (continued) 06/07/09 End view of 1 st Rough Form
  18. 18. Roughing, Heat Treat and Finish (continued) 06/07/09 <ul><li>End view of first rough form used to cut one 30° angle with Stanley 9 1/2 block plane </li></ul><ul><li>End view of second rough form used to complete triangle cross section with Record Low-Angle block plane </li></ul>
  19. 19. 06/07/09 Roughing, Heat Treat and Finish (continued)
  20. 20. Roughing, Heat Treat and Finish (continued) 06/07/09
  21. 21. Roughing, Heat Treat and Finish (continued) 06/07/09
  22. 22. Roughing, Heat Treat and Finish (continued) 06/07/09
  23. 23. Roughing, Heat Treat and Finish (continued) 06/07/09 Final test strips with “New” rough mill
  24. 24. <ul><li>After heat treat cycle, adjustable steel forms are set to required taper dimensions </li></ul><ul><li>Finish plane and scraper used to cut strips to final size </li></ul><ul><li>Block plane is used to remove material to within .020” of the form surface </li></ul><ul><li>Scraper, set to remove .001” chip is used to finish strip flush with form surface </li></ul>Roughing, Heat Treat and Finish (continued) 06/07/09
  25. 25. Roughing, Heat Treat and Finish (continued) 06/07/09 Low-Angle block plane to begin finish planing
  26. 26. Roughing, Heat Treat and Finish (continued) 06/07/09 Scraper to complete finish planing
  27. 27. <ul><li>Block plane vs. Scraper shavings </li></ul><ul><li>Finished tip strip – typically .035” or thinner than a slightly worn Roosevelt dime </li></ul>Roughing, Heat Treat and Finish (continued) 06/07/09
  28. 28. The Glue Job 06/07/09 All 3 sections cleaned, taped and ready to glue
  29. 29. The Glue Job <ul><li>After all strips are finished planed, they are cleaned, arranged in the proper sequence and taped together before gluing </li></ul><ul><li>Nyatex Epoxy is used – applied liberally (not by Hillary) worked into the bamboo surfaces </li></ul><ul><li>Strips are bound again, straightened and allowed to cure for 24 hours </li></ul><ul><li>Final heat treat sets epoxy permanently! </li></ul>06/07/09
  30. 30. The Glue Job 06/07/09
  31. 31. The Glue Job 06/07/09
  32. 32. Final Assembly & Hardware <ul><li>Several steps now required to assemble rod hardware </li></ul><ul><li>After the epoxy is heat cured, the binding thread is removed and the sections are block sanded to remove glue and enamel surface </li></ul><ul><li>The ferrules are prepped and rod sections dressed to accept ferrules </li></ul><ul><li>The reel seat and grip area is cleaned and prepped </li></ul>06/07/09
  33. 33. Final Assembly & Hardware 06/07/09 Before & after block sanding & tung oil
  34. 34. Final Assembly & Hardware 06/07/09 Ferrules prepped and sections ready for epoxy
  35. 35. Final Assembly & Hardware 06/07/09
  36. 36. Final Assembly & Hardware 06/07/09 <ul><li>Walnut Burl slab used for turning reel seat fillers. </li></ul>
  37. 37. Final Assembly & Hardware 06/07/09 Finished Birds-Eye, Madrone & Maple Burl fillers
  38. 38. Final Assembly & Hardware 06/07/09
  39. 39. Guides, Wrapping and Varnish <ul><li>Now very close to completing the rod, it’s time to wrap & finish guides and varnish the completed fly rod </li></ul><ul><li>Silk thread used for a smooth, fine finish </li></ul><ul><li>Hard Chrome snake guides in Bright or Bronze </li></ul><ul><li>Mildrum Carballoy or Agate Strippers </li></ul><ul><li>Epifane spar varnish in a dip tube for final high gloss finish </li></ul>06/07/09
  40. 40. Guides , Wrapping and Varnish 06/07/09
  41. 41. 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!
  42. 42. Guides, Wrapping and Varnish 06/07/09 <ul><li>Signature wrap is used to finish front of grip – open loops represent line weight </li></ul><ul><li>Finish wrap to secure ferrule tabs </li></ul>
  43. 43. Guides, Wrapping and Varnish 06/07/09 Classic colors of Pearsall’s Gossamer Silk Thread
  44. 44. Guides, Wrapping and Varnish 06/07/09 Variety of Golden Witch Agate & Jasper Strippers
  45. 45. Guides, Wrapping and Varnish 06/07/09 <ul><li>Varnish dip tank & dust proof enclosure </li></ul><ul><li>Low R.P.M. motor extracts rod from tube at 2 inch/minute </li></ul><ul><li>Rod is paused at guides to prevent sagging </li></ul>
  46. 46. Guides, Wrapping and Varnish 06/07/09
  47. 47. Bags, Tubes and Final Items 06/07/09 Soft cotton rod bag hand sewn for each rod
  48. 48. Bags, Tubes and Final Items 06/07/09
  49. 49. Bags, Tubes and Final Items 06/07/09 Powder coated tube, vent seal cap & fleece sock
  50. 50. The End 06/07/09 If I used a Bamboo Rod, I’d be holding the big Rainbow !