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Gundalba

Cork handle replacement

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10+ years ago, I've build this AFAW Estuary which I loved very much and did 99% of fishing with it since.

One thing I regretted was using some left-over (rejects) cork rings for its handle which did great job but its lack of quality showed up somewhat prematurely, in my opinion.

So I've decided to get some better ones and replace them as rest of the rod are holding up just great.

Here are some pics I took along the way and hope you will enjoy them, may be learn (or avoid) a few things as well.

I think I will divide them in a several series since there are more than couple pics I took. ;)

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Thanks for the photos . . . good step-by-step.

 

If you shape cork on mandrels you can easily drill out the center to a larger bore with a forstner bit for less reaming.  I've never liked reaming starting with the 1/4" bore if the final ID is a lot larger.

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On 7/30/2019 at 7:06 AM, rreelman said:

I would have cork taped the entire butt length--easy--on to next project--rreelman

That sure will make things easier and cheaper, though I had to have those corks where it matters for me... I am sure everyone have their preference and the beauty of building one's own rod is being able to have it exactly the way you want.  ;)

On 7/30/2019 at 0:53 PM, Mangomania said:

Thanks for the photos . . . good step-by-step.

 

If you shape cork on mandrels you can easily drill out the center to a larger bore with a forstner bit for less reaming.  I've never liked reaming starting with the 1/4" bore if the final ID is a lot larger.

Agree, so I've used 3/8" drill bit to hollow out the bore before the reaming. I haven't tried forstner bit as I felt it might ruin those corks going too aggressive with larger diameter.

Does forstner cuts better(cleaner?) on corks? 

 

Anyhow, some more pics covering rest of the work done on foregrip and first collection guide.

Took me a while to get back to it but was worth it.:heart:

 

 

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Forstner bit works very well for drilling out individual cork rings prior to gluing.

 

Looks like that first guide is really locked in place.

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Posted (edited) · Report post

On 8/19/2019 at 4:28 AM, Mangomania said:

Forstner bit works very well for drilling out individual cork rings prior to gluing.

 

Looks like that first guide is really locked in place.

Aaaah, so you drill them out before the gluing them together. Doesn't it make it harder to align them when clamping for glue up?

 

All the guides on that rod are locked in just like that.

For ease of adjusting alignment, wrapping and most of all to keep all the other tiny footed titanium guides used on this build secured. This was the only non-Ti guide as there was no Ti guide available at this ring size.

Clue is on third picture down.... ;)

On 8/19/2019 at 8:39 AM, Mike Oliver said:

G

 

Just a suggestion. Placing a blank in any vice is very risky. 

 

Mike

Very good point Mike, I wouldn't recommend using vise in most cases either.

The vise used on the pic has leather and wood layer on contact point plus this particular one is a light duty one which makes adjustment much easier.

Even then, I was being extra careful to have just enough grip to avoid slip....

Edited by Gundalba

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Aaaah, so you drill them out before the gluing them together. Doesn't it make it harder to align them when clamping for glue up?

 

No.  I use hex head bolts or all thread with wing nuts and washers to clamp rings for gluing.  Just use the same size as the hole you drill in the cork.

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