TOOLS, GADGETS & METHODS

(also see SELECTING & SPLITTING BAMBOO FOR RODMAKING)

Click on images for a larger picture.

ADJUSTING THE PLANING FORM
The use of precision drill rods and a dial indicator is the most accurate method for setting the planing form. I use a Mitutoyo back-plunger dial indicator, model #1156 with my own custom-built base.

 

A set of blank drill rods in sizes 1/32" to 5/32" will handle the tapers for most rods. The depth of a 60-degree "V" groove is equal to 1.5 times the drill rod diameter.

 

 

THE PLANE
This is the original self-leveling plane which was designed and built by John Bokstrom. It's a Record 9-1/2 plane with the guide assembly pinned in place just behind the blade (the original cap iron was trimmed to reduce height). The guide wheels hold the sole of the plane level with the top of the planing form enabling the rodbuilder to achieve perfect 60-degree angles with little effort. The self-leveling devices can be purchased here.

 

HOLLOW BUILDING
Building hollow bamboo fly rods is done for keeping the rod as light as possible. Hollow-fluting is one of several ways to hollow the rod, but the main advantage to fluting is that it provides more surface area for gluing than other methods of hollowing.

My hollowing device was made using a Dremel power tool. The device pivots radially up and down, and wall thickness can be changed by simply turning the adjustment screw. The Dremel's shaft is supported by a ball-bearing which "floats" in the plastic housing. I shimmed the outer race, and now there is virtually no play. I can set the tool for .070" wall thickness and that's what I get.

 

When the milling is finished I brush the grooves with a fine wire brush to remove any splinters.

 

 

 

GLUING THE STRIPS
There are many types of glue, and rod makers have their own preference. My previous choice, Borden's UF-109, has been discontinued so I now use Casco-Resin 5H. It is a two-part waterproof marine glue and has proven to be completely adequate for the purpose. When mixed as recommended with the supplied catalyst, it has an open time of about 20 minutes.

 

The bamboo strips are held together with several pieces of masking tape which is then cut between the same two strips at all locations allowing the sections to be spread open for gluing. The tape holds the strips in place while the glue is applied with a stiff-bristled brush.

 

 

THE BINDERS
This compact 4-string binder is used for wrapping string tightly around the strips when binding them prior to heat-treating or after gluing. The four strings wrap in two directions at the same time so the process requires only one pass. The foot-controlled electric motor frees both hands for passing the strips through the spindle hole. It is built out of aluminum, brass and UHM plastic, with a few stainless steel fittings.

 

This binder is based on the one designed by Garrison. It requires that the bundle of cane strips be put through twice, with the drive cord reversed for the second pass. When tuned and operated properly, it will produce straight, twist-free rod sections.
It is made of aluminum, with stainless steel screws and some brass fittings.

 

GLUING THE CORK HANDLES
Cork is the bark of an oak tree known botanically as quercus suber. It is an evergreen which grows in commercial stands only in areas bordering the Mediterranean Sea. Of the important cork producing countries, Portugal supplies approximately 50%, Spain 25%, and the balance is divided between Algeria, France, Morocco, Italy and Tunisia.

The cork press is made of anodized aluminum with brass fittings.

When the glue is dry, the handles are turned to shape on a lathe.

 

 

FINISHING
The rods are dipped in Helmsman Spar Urethane and withdrawn at a rate of 4 inches per minute (the rate of withdrawal depends on the viscosity of the urethane). The dip process provides greater surface protection than brushing or spraying and allows the rod to be redipped even when tacky. My shop floor has a four-inch hole, 34" deep, which accomodates the five-foot tube of urethane.

The withdrawal motor assembly is mounted low on the wall for greater visibility when lowering butt sections as close as possible to a corked handle.

After dipping, the rod sections are hung to dry in a heated, dust-free cabinet.

 

 

 

WRAPPING THE GUIDES
The guides are secured in place with fine, translucent, silk thread, which passes through a tensioner to keep the thread taut. Then the wraps are given numerous coats of spar urethane until smooth and glossy. The grain of the bamboo can usually be seen through the wraps unless the thread is very dark.

 

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Web site created and managed by Ron Grantham. Updated 01/06/2010.