Cross cut, usually to 6’, 4’ or 3’ lengths
Mark each cut relative from bottom to top. ½-hrs
Hand split sections into 14 to 22 strips.
Mark each strip relative to its position & section.
Keep each set of strips with its own section. 1-hrs
Sanding the sections.
File or sand excessive amounts from sides.
Remove & sand the internal node dams.
File and sand external nodes. 2 to 3-hrs
Square and size the strips.
Rough cut the sides to the width, different for each section.
Rough mill top & bottom to needed thickness. 2- hrs
Soaking in water.
2 to 4 hours, depending on how soft you need it.
If soaked to long, simply let it dry a bit.
Bundle and tie up if you’re stopping at any point. 2 to 4- hr
Rough plain the strips.
Plane or mill the strips to create 60 degree triangle.
Butt and Tip will have different width & thickness. 3 to 4- hrs
Heat treating the strips
Place strips, bundled or tied to extrusion in oven.
Bake @ 185 degrees for 35-55 minutes.
Checking the moisture content for proper percentage. 1 to 2- hrs
Set planning form for taper of each section.
Check plane blades for sharpness.
Plane each section. Re-set for each section. 4 to 7 hrs
Check all strips to prepare for laminating
Hollow plane at this point, if you’re going to. 4 to 7 hrs
Strip blank laminating
Layout on paper, apply glue to strips Note: If you use URAC 185, make sure humidity is above 20% while drying.
Send glued blanks through binder, Roll and straighten bound blanks to take out twists & bends.
Dry, 24 - 48 hr. cure time 3 - 4 hrs
Scrape and sand rod blank surfaces to remove binder cord, adhesive material and enamel.
measure and cut blanks to required length
straighten rod sections, use a little heat if necessary 3- hrs
Measure and mark ferrule stations on rod sections.
Size and turn respective ferrule stations to fit (by hand or Machine)
Clean all internal ferrule parts thoroughly
Crown and feather ferrule tab serrations, clean again
Allow 24 to 48 hours drying time. 2 to 3- hrs.
Lap & fit ferrules. (Female to male slide) 1- hrs
Varnish and finish preparation.
Sand and clean blanks dust free.
First coat, dipped or hand rubbed, always allow 2 to 5 days drying time.
Lightly sand, and clean dust free.
Repeat for total of 3 to 5 coats 1 to 2- hrs
Determine guide spacing. ½ to 1- hrs
Find the spine in the rod.
Install guides on stiff side for longer cast, or soft side for accuracy.
Install the Reel seat, grip, winding check.
Attach the tip-top last. 1 to 2- hrs
Determine guide spacing. 1 to 2- hrs
Attach line guides and hand-wrap all thread windings. 4 to 7- hrs
Coat/seal all thread windings.
Clear wraps, apply 2 coats of CP to thread windings.
Apply 3 to 6 coats, process varies from maker to maker, place to place.
Also depending on the climate! Test on something first before doing the rod!
Translucent wraps, 2 coats of diluted solution.
2 to 3 coats of undiluted solution.
2 coats per day, maybe? Always allow at least 12 hours, preferable 24 to 36 hours between each coat.
5 to 7- hrs
Signing the rod 1- hrs
Final coats of varnish/ urethane. Allow 7-10 days for finish to "semi-cure".
Full curing time for most varnish products is typically 1-½ to 3 months)
43hrs to 55hrs plus
Final rod inspection.
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