Ted Barnhart provides instructions over 44 pages on building a universal ferrule using composite materials like graphite cloth, Kevlar, and carbon braid sleeves. The document covers supplies needed, building different types of ferrules using various composite cores, and finishing techniques. It emphasizes documenting standards to save time and includes sources for composite materials.

1. BUILDING THE
UNIVERSAL FERRULE USING
COMPOSITE MATERIAL
Ted Barnhart
September 6, 2014
www.TedRBarnhart.com
Phoenix, MD
2014 Rod Makers Gathering
Catskills Fly Fishing Center and Museum

2. 2
The
Beginning
of an Idea
2Building a Universal Ferrule by Ted R BarnhartSeptember 2014

3. 3
Types of Composite Materials
3Building a Universal Ferrule by Ted R BarnhartSeptember 2014

4. 4
Supplies and Tools You Will Need
Building a Universal Ferrule by Ted R Barnhart 4September 2014

5. 5
Key to Supplies List
Phoenix, MD
5
1. Leather punch 13. Scissors
2. Cling wrap 14. Clothes pins
3. Roller pad 15. 5/30 minute epoxy
4. Small roller 16. Wood putty
5. ”T” Tool 17. Long set epoxy
6. Contact cement glue pattern 18. Ceramic mix plate
7. Contact cement 19. Spoons, mixing vessel
8. Lead weights 20. Brush
9. .0045” thick Paper strips 21. 3/4” Shrink tape
10. 1/8”, ¼”, .6” long pointes dowels 22. 1/4” Artist masking tape
11. Wire hook 23. Digital thermometer
12. ½” clips 24. Razor cutter
Building a Universal Ferrule by Ted R BarnhartSeptember 2014

6. 6
Jig - 60” x 6” with 8”
cut out for hot box
Leveling the Jig
Jig with hot box in place
September 2014 6Building a Universal Ferrule by Ted R Barnhart

7. 7
Hot Box
7Building a Universal Ferrule by Ted R BarnhartSeptember 2014

8. 8
Gram Scale
Hair Dryer
Pattern Support Pad
Rheostat
Other Tools
Building a Universal Ferrule by Ted R Barnhart 8September 2014

9. 9
Jig with Pattern Support in Place
September 2014 9Building a Universal Ferrule by Ted R Barnhart

10. 10
• Document your
“Standards” as you go
to save time & rework
10Building a Universal Ferrule by Ted R Barnhart
• Update your “Standards”
as you develop new
techniques
September 2014
Create a Standards Notebook

11. 11
Documenting Your Standards
September 2014 11Building a Universal Ferrule by Ted R Barnhart

12. 12
Burnish the butt of the tip
and the tip of the butt
Varnishing the tip
of the butt – 3”
Preparing the Tip of the Butt
Building a Universal Ferrule by Ted R Barnhart 12September 2014

13. 13
Cutting ½” Wide Piece of Cling
Wrap
Building a Universal Ferrule by Ted R Barnhart 13September 2014

14. Wrapping cling wrap around
butt of tip 3”
(over lap by 50%)
Applying a dab of contact
cement
Twisting cling wrap
at end of butt
Cutting twisted
cling wrap
Building a Universal Ferrule by Ted R Barnhart 14September 2014

15. 15
Cutting a 26” Strip of ¾” Shrink Tape
into Three ¼ “ Wide Strips
Building a Universal Ferrule by Ted R Barnhart 15September 2014

16. 16
Building a Universal Ferrule
Using GRAPHITE CLOTH
And With ¼ “ Polyolefin Shrink Tubing
as the Core.
(Refer to “Standards” for length of the shrink tube for 7’6” fly rod.)
16Building a Universal Ferrule by Ted R BarnhartSeptember 2014

17. Using a 12” long 4.5 mil thick strip
of paper, wrap paper seven (7)
times around tip of butt to
determine length of graphite cloth
pattern
For pattern construction, refer to
universal ferrule “Standard” for
7’6” fly rod
Pattern A-1 , A-2
Pattern A-1
(outline with ¼” artist masking tape)
Building a Universal Ferrule by Ted R Barnhart 17September 2014

18. Building a Universal Ferrule by Ted R Barnhart 18September 2014

19. Building a Universal Ferrule by Ted R Barnhart 19
Contact cement is applied on the
edge of the graphite pattern
Contact cement is applied
across
this middle of the pattern
September 2014

20. The pattern is cut out and
cut into two pieces. The
contact cement holds the
pattern edge together.
The two pieces of the
graphite pattern.
Building a Universal Ferrule by Ted R Barnhart 20September 2014

21. Lining up the tip of the
butt in the jig
Locating the position of the
shrink tubing on the butt
of the rod tip
Building a Universal Ferrule by Ted R Barnhart 21September 2014

22. 22
Using the leather, punch
holes in the shrink tube.
See “Standards” for the shrink tube
overlap on butt of tip (1 ½“).
Using the leather punch
Building a Universal Ferrule by Ted R Barnhart 22September 2014

23. Apply 30 minute epoxy
to butt of tip
Slip shrink tube over butt
end of tip to masking tape
Building a Universal Ferrule by Ted R Barnhart 23September 2014

24. Insert tip of butt into
shrink tube
Shrink tube in place,
tip and butt secured in jig
Heat shrink the shrink tube
using hair dryer
Shrink tube ready to
apply 1st pattern
Building a Universal Ferrule by Ted R Barnhart 24September 2014

25. To apply contact cement to shrink
tube, hold the 1st pattern in place
Apply contact cement to opposite
side of 1st pattern
Apply epoxy to the opposite
side of pattern
Attach the pattern to the shrink tube
Building a Universal Ferrule by Ted R Barnhart 25September 2014

26. Roll the epoxy on the pattern Using the “T” tool, fold the
pattern around the rod
Finish the folding of the pattern Clip the edge of the pattern in
place using clothes pins
Building a Universal Ferrule by Ted R Barnhart 26September 2014

27. Clothes pins hold the pattern in
place & clips secure the shrink tape
Wrapping the shrink tape right to
left
Shrink tape secured at both
ends with clips
Hot box set to heat for 25 minutes
temperature controlled 170-180⁰F
Building a Universal Ferrule by Ted R Barnhart 27September 2014

28. 28
First pattern completed - Unwrapping the shrink tape
First Pattern Completed
Building a Universal Ferrule by Ted R Barnhart 28September 2014

29. Applying contact cement to
top of 1st pattern
Applying contact cement to opposite
side of 2nd pattern
Apply epoxy to opposite side of 2nd
pattern cover only width of roller
Cementing pattern to top of 1st pattern
Building a Universal Ferrule by Ted R Barnhart 29September 2014

30. Applying epoxy to the pattern Using the “T” tool, fold the pattern
around the 1st pattern
Using clothes pin, hold pattern in place Wrap the shrink tape right to left
& move clothes pin left to hold the
shrink tape in place
Building a Universal Ferrule by Ted R Barnhart 30September 2014

31. 2nd pattern ready to be heat set Hot box is in place; set
temperature control to 170-180⁰F
for 25 minutes
Unwrapping the shrink tape.. Butt pulled from the ferrule
Building a Universal Ferrule by Ted R Barnhart 31September 2014
Note some epoxy seeping
out

32. 32
Inspecting the Finished
Ferrule…
32Building a Universal Ferrule by Ted R BarnhartSeptember 2014

33. 33
Building a Universal
Ferrule Using KEVLAR
CLOTH
With ¼” Carbon Braided Sleeve as
the Core.
33Building a Universal Ferrule by Ted R BarnhartSeptember 2014

34. 5” Length of carbon braid
sleeve
Apply contact cement to carbon braid
sleeve to hold the threads together
Let the contact cement set Cut the carbon braid sleeve
Building a Universal Ferrule by Ted R Barnhart 34September 2014

35. Use a pointed dowel to
spread out the cement fiber
Apply epoxy to the butt of the tip
Compress the
carbon braid
sleeve and
slide it onto the
butt of the tip
Building a Universal Ferrule by Ted R Barnhart 35September 2014

36. 36
Slide the tip of the butt into the sleeve
and secure the butt to the jig.
Hold the left end of the sleeve and
work it to the right over the tip of the
butt.
Smooth out the sleeve by
holding the left end and sliding
your fingers to the right.
Inserting the Butt into the
Sleeve
Building a Universal Ferrule by Ted R Barnhart 36September 2014

37. The carbon braid sleeve is ready
to be coated with an epoxy
Using the roller, apply a thin
coat of epoxy
Clip the shrink tape on the left side
and wrap the shrink tape to the
right
Set heat for 20 minutes - control
temperature 170-180⁰F
Building a Universal Ferrule by Ted R Barnhart 37September 2014

38. Applying contact cement to the top of the core
The carbon braid sleeve core is
ready to unwrap the tape
The core is ready to attach to
the Kevlar pattern
Building a Universal Ferrule by Ted R Barnhart 38September 2014

39. Lay out pattern 1 and pattern 2.
Trim the edges of the pattern 2 by
1/8”
Tape out the pattern using
¼” artist marking tape
Overlay pattern 2 and apply contact
cement to the edge and cut out
pattern
Turn over pattern & apply a thin line
of contact cement to top of pattern
roll on a 1” wide layer of epoxy
Building a Universal Ferrule by Ted R Barnhart 39September 2014

40. Tack the pattern to the core Apply epoxy using the roller
Using the “T” tool, wrap the pattern
around the rod
Wrap the pattern with the shrink
tape from right to left
Building a Universal Ferrule by Ted R Barnhart 40September 2014

41. Ferrule ready for the hot box Set timer for 25 minutes – control
temperature 170-180⁰F
Un-wrap the shrink tape
Building a Universal Ferrule by Ted R Barnhart 41September 2014

42. 42
Removing the Butt From the
Ferrule
Building a Universal Ferrule by Ted R Barnhart 42
Butt ready
to be
pulled from
ferrule
Butt pulled
out of
ferrule
September 2014

43. 43
Finishing The Universal Ferrule
43
1. Hexagonal Bamboo rods:
– Composite material is graphite or fiberglass cloth
– File off the rough spots followed by sanding by hand
– By machine, lath using a sanding board
2. Pentagonal and quad bamboo fly rods:
– Composite is graphite or fiberglass cloth
– Use a file or sandpaper to smooth rough spots
3. For all universal ferrules made with Kevlar:
– All ridges can be smoothed out by a high speed grinding wheel
– Gilding with gold or silver leaf works well to cover the Kevlar
4. For ALL Universal Ferrules:
– Use Elmer putty to fill small holes
– Add bead of 5 min. epoxy at the transition of the ferrule & the bamboo
– You can paint or gild the ferrule.
– Graphite ferrule can be left black
Building a Universal Ferrule by Ted R BarnhartSeptember 2014

44. 44
Sources for Composite Materials
44
1. Graphite cloth
CST / Composite Structure Technology
 1-800-338-1278
 http://www.cstsales.com/contact.html
 C-131 2.90 Ounces/sq. yd. $51.20 per ft. (2007) 4.5 mils
 They have shrink tape
2. Kevlar and fiberglass cloth
Wicks Aircraft and Motorsports
 1-618-654-7447
 http://www.wicksaircraft.com/index.html
 120k Kevlar cloth, 1.8 oz, yd plain weave
 $30.64/sq. yd., 3.5 mils
 1522 fiberglass cloth, 3.74 oz/5yd
 $6.69 sq. yd., 5 mils
 1088 fiberglass cloth 1.45 oz/ sq. yd.
 $7.56/sq. yd. 2 mils
Building a Universal Ferrule by Ted R BarnhartSeptember 2014

45. 45
Sources for Composite Materials
(Continued)
45
3. Braided carbon sleeve
ACP Composites
 1-925-443-5900
 http://www.acpsales.com/OnlineStore.php
 250” ID Braided carbon sleeve
 $.72/ft.
 .500” available
4. 1/4” shrink tape
Home Depot or Electrical Supply Stores
Building a Universal Ferrule by Ted R BarnhartSeptember 2014

46. TED BARNHART
Fishing the
Firehole River in
Yellowstone National
Park
WWW.TEDRBARNHART.C
OM