How to Build Fly Rod Handles
Building a rod from scratch is a great hobby and stress reliever. Building your own fly rod and handle is an especially fulfilling project for the do-it-yourselfer. The hobby of rod building and fabricating your own fly rod handle is enjoyable, rewarding, is less expensive than purchasing a finished rod and can give you a memory of a lifetime to pass the finished product along to a family member or a good friend.
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Things You'll Need
- One small electric drill One 1-inch-by-6-inch-by-14-inch pine board Two 1-inch-by-6-inch-by-6-inch pine boards Four No. 8 x1 ½-inch wood screws One 3/8-inch-by-18-inch long all thread rod Two large 3/8-inch flat washers Two 3/8-inch hex head nuts One fine wood rasp or file One package various grit sand paper 13-14 cork rings (probably 1 ¼-inch-by-½-inch-by-¼-inch size)
Instructions
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1
Begin by fabricating a pivot stand with the pine boards. The two 1-inch-by-6-inch-by-6-inch pine boards need a 1-inch V-notch cut in the center on one end of each board. Place each 1-inch-by-6-inch-by-6-inch pine board on an end of the 1-inch-by-6-inch-by-14-inch pine board at 90 degrees to make a stand for the handle spindle to rotate in freely. Secure the boards with the No. 8 x1½-inch wood screws
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2
Using the 3/8-inch-by-18-inch long all thread rod with a 3/8-inch hex head nut and flat washer installed on one end, thread the cork rings one at a time, applying glue between each ring until all are secure and desired handle length is complete. Install the second flat washer and 3/8-inch hex head nut and tighten to secure cork ring adhesion.
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3
Draw on a sheet of paper or construction paper a template of the desired rod handle shape and design.
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Place one end of the all thread rod in your small 3/8-inch drill and arrange support for the drill to allow the rod handle spindle to rest in the pivot stand you constructed earlier.
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Using the template and a pencil, lightly make the shape of the rod handle design on the cork so you can begin shaping the handle.
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Start the drill at a slow speed and lock the trigger so as to act similar to a lathe. Using the rasp or file, begin shaping the cork to match the template.
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Use the sand paper to smooth the cork to the final finish.
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Remove the spindle from the drill and remove one of the 3/8-inch hex head nuts and flat washer.
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Unthread the completed handle assembly from the all thread rod, then glue the completed assembly onto the rod blank along with the reel seat and ferrule to complete your new rod. Congratulations on your project and good fishing.
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Tips & Warnings
There are two ways of constructing a rod handle. The first and most unforgiving way is to construct the handle on the finished rod blank being used. (If you make a mistake it is very difficult to correct or change, so you'll probably have to live with it or tear it apart very carefully). The second method is the dowel rod or spindle method. The unit is constructed, then mounted on the rod blank.
