Tuna Rod Build Start to Finish

[dunn6253]

Chum, could you send me the same PM about the bent vs. straight if you could.

I think shoe got most of his parts from mudhole and one other place, it is in a earlier post of his.

[shoefish]

Put in some more time tonight. This is when it gets fun. Putting on the underwraps is when your rod really starts to take shape.

Wrapping the guides is done with nylon thread. There are different companies that make thread specifically intended for rod building. I use Gudebrod.

The threads are sized from A to... actually I don't know how high they go, I only use up to D. A is the smallest diameter, and it increases with the letter. You generally use A as the underwraps, and then build on top of them with larger diameter. This is done so that the over wraps don't fall between the wraps beneath them, and because you want the largest diameter (and hence the strongest) to wrap the guides.

There are basically two different kinds of thread- regular and metallic. The regular is, well, regular, and the metallic is reflective in the sunlight.

First thing I want to do is to frame the abalone a bit. To do this I'm going to do a border with black, with a silver highlight.

To start the wrap, you take one full wrap around the blank, and then cross the thread over on itself and continue to wrap


When you get to the point that you're ready to finish, create a loop with a separate piece of thread (I usually use D thread for this because it's stronger)


Tuck the loop under the working piece of thread, with the loop on the side that you are wrapping towards


Then continue wrapping for a minimum of 3 wraps. When you are ready to end it, place your finger on the threads so it doesn't unwind, and cut the thread. Then pass the end through the loop...


And pulling on the tag ends, pull the loop through


Using the same method, I added a silver band on either side to make the shell pop


Next up, the underwraps. The method here is the same, and you can add any highlight colors that you like

Here is how the stripping guide will butt up against the shell


Once underwraps are complete, you should put a coat of your epoxy on before continuing.

Wraps prior to flex coat.


Wraps with one coat.


So now the rod will dry overnight, and then it will be time to prep the guides.

[clt_capt]

Got a chance this evening to try the abalone the way you did it - AWESOME. No cracks. My stress level was also a lot less - I didn't have to worry about losing a big flake of shell that would look bad.

GREAT TIP. As soon as I can get the wraps on I'll vet some pics up.

Thanks - Great thread.

[shoefish]

Originally Posted by clt_capt

Got a chance this evening to try the abalone the way you did it - AWESOME. No cracks. My stress level was also a lot less - I didn't have to worry about losing a big flake of shell that would look bad.

GREAT TIP. As soon as I can get the wraps on I'll vet some pics up.

Thanks - Great thread.

Dude that is great news! I'm happy to hear that it's so reproduceable. Wait until you put your first coat of flex coat (or whatever) on it- without the cracks it just plain rocks. Looking forward to the pics!

[flatliner]

Glad to see that you areing as much fun with the abalone as I am! See, there is more than one way to skin a cat! Awesome news!

Keep up the good work. I have 5 rods that I am doing now with more abalone. I still use my method as I am getting better results, but I get an even better look now! This veneer is awesome!

Tight wraps,
Kevin

[clt_capt]

Here are a couple of Gaffs that I'm working on. For the abalone, I used the method Shoe described - Works GREAT.

For the top gaff, the shell veneer is a fine grain - Absolutely no cracking. The lower one uses an angel wing veneer with a much bigger grain. There were a few small cracks - just where the overlap is.

Having tried other methods, I like this.

These have just 1 coat of Light Flexcote. Once I put the hooks on and reinforce the tip, I'll put on 3 more coats.

[shoefish]

Wow man, those look sweet!

[shoefish]

Yesterday Kevin and I decided to get together to get a jump on his rods. These are the first rods that Kevin has built, and I have to say he's a fast learner.

For the butt wrap, Kevin wanted to do a diamond pattern. The first thing that we did was to do an underwrap. We measured up the distance from the end of the EVA grip, to where the end of the first guide will be and marked that with tape. Then, using the same method you guys have seen before, Kevin ran that distance with metallic red.

The next step is one that you should take your time on, as it will set the course for the rest of the wrap. If you're off, it will be 10 times harder. Essentially all you do is move the thread laterally as you turn the rod. This will create "X"s that form the base for nearly all patterns. You want to make sure that all of the "X"s are lined up equally.


To do a diamond pattern, you will use this basic "X" and then lay one thread above the original thread, followed by one thread below the original thread.


You continue this pattern, wrapping one thread above and one thread below. You can change colors after you complete a "set"- that being one above and one below. You can see the diamond starting to form where the threads intersect




Once you get to the point that you are happy with the pattern, you can do one final "set" with black. Kevin likes to say that this makes the pattern pop.


When that is done you do a standard wrap on the top and the bottom of the pattern to seal the deal, and you're done. Throw on your underwraps, and put on the flex coat.


While Kevin was doing his rod, I had my other two abalone set ups to get started. I used the same vinegar method that I had used before, only yesterday being a cooler day, I put the cut shell in the vinegar and put the whole thing in the microwave. For about two hours I would nuke the whole thing for 20 seconds whenever the vinegar cooled off. Then I did the same hot water bath, and it worked just as well. It's nice to know that you can get the same results without having to let it soak for a long time.

Here is one of the other set ups. I'll be using a metallic green and gold for the highlights on this rod


Then I did a "standard" looking abalone. Here are all three together


Sitting there looking at these, I had a bit of a light bulb go off...I had more "prepped" abalone and wasn't sure how to use it. Then I looked at the section of aluminum above the ferule, and said...hmmmmm.....


Looks good to me! Here's what all three look like


So now I need to finish the underwraps on mine, and kevin needs to get to work on the second one. Then we'll be prepping the guides and getting those put on.

More to come soon....the tuna reports are already rolling in, so we need to get these things done pronto

[canyonjunkie]

looking awesome shoe! its a work of art. i think next summer I might try to get into it. This summer i need to try to get into college! but those rods of yours are so pretty i would be scared to fish them!

[tunakiller 4 hire]

Man I got to learn how to do that it would keep me busy all winter.