How many "correct" ways are there to build a bamboo fly rod? A recent online conversation led to several folks sharing broad outlines of the steps they take in making a rod. I suspect the steps I follow are different from those followed by the owner of this blog, and perhaps from almost any other rod maker. For what it's worth, here are the steps I usually take as of late 2008. And of course, any of these are subject to change as better ideas come along. Read my how to series on making rods at http://www.globalflyfisher.com and see if you can determine how many things I have changed in just the last few years.
Choose culm and cut to length
Power sand node ridges
Flame, or don't flame
Split by hand, start with nippers.
Aim for 20 butt section pieces, and 28 tip section pieces.
Stagger for 3x3 or 2x2x2 node spacing and trim to final length, plus 4"
Press nodes dry, without a depression for relief
Rough to equilateral triangles with beveller
Temper at rough equilateral triangle stage, before tapering
Bind into heat treating fixtures by hand
Forced hot air oven, 375*F for 11 minutes or until things smell right
Initial taper with beveller
Hand plane to final dimensions
Five identical planes used set for .001" - .005" shavings
Diamond stone sharpening and leather wheel final honing
Wipe clean with mineral spirits on a golf glove
Epon glue
Four string binder (nylon string)
Roll on flat surface to straighten
String removed afer 8 hours
Excess glue removed with alcohol and a thumbnail
Re-bind, heat set 3 hours at 185*F
Sand any glue with Fine SuprSandr
Sand blank with 400g
Tweak straightening with heat gun on lowest setting
Cut ferrule stations on lathe with dowel cutters.
Install ferrules (CSE step-downs, mostly)
Ferrule glue -- Rod Bond Epoxy Pin all ferrules
Fit male to female in lathe with Grobet files
Trim till each section exactly same length
Build grip on blank. Gorilla Glue
Dip two coats P&L #61 polyurethane varnish, very slow retrieval
Scotch-brite between coats, held in block to keep corners sharp
Determine guide spacing through static deflection.
Snake Brand guides (bronze) Pac Bay tiptops
Wrap with old Gudebrod 00 or YLI 100 silk, tip with Pearsall's Gossamer
Finish wraps with thin epoxy first coat, poly for rest. Usually no color preserver
Sand wraps flat with 600g paper
Sign with Pigma Micron .005 pen
Dip final coat(s)
Polish specks with Finesse-It
Install reel seat and filler with Rod Bond and a pin.
Locally made bag
Landmark Aluminum tube