How a Graphite Fly Rod is Made

For those of you who are just now entering the sport of fly fishing, you may find yourself bewildered by the wide range of graphite fly rods available on the market today such as those found at chain stores like Wal-mat to the top end rods from manufactures such as Orvis, Winston, and Sage. Also, you may find yourself wondering why these rods have such a wide price range?

Well, the answer to that question is that manufacturing a good graphite fly rod requires a considerable amount of technical expertise, skilled manual labor, and special materials and equipment. Thus, inexpensive graphite fly rods employ inexpensive materials, cheap labor, and poor quality control whereas top quality graphite fly rods employ top quality materials, highly skilled labor, and meticulous quality control.

In addition, the process of designing and producing a graphite fly rod is technically demanding and requires special equipment. To start with, a manufacturer must first decide what length and line weight the rod is to be designed for and then they must develop a taper that meets those specifications. Therefore, they start by choosing either a progressive taper or a compound taper design. The progressive taper design employs a gradual, even, taper that progresses smoothly from the tip to the butt of the rod blank. Whereas a compound taper employs a graduated taper from tip to butt that results in the rod blank being stiffer in the areas where it is needed and less stiff in the areas where it is not (more on this subject later). Then, once the desired specifications are determined, a tapered steel rod called a mandrel is precisely machined to meet the needed specifications and then the building process starts.

The first step in the actual building process, it to cut a piece of graphite cloth which has been impregnated with a special resin in the shape of a triangle. In the case of progressive tapers, the three sides of the triangle all have straight edges but, in the case of the compound taper only two sides of the triangle have straight sides while the third side will have a compound edge consisting of several straight edges (see illustration).

Then, after the graphite cloth is cut to the required size and shape, it is laid out flat on a large table and the steel mandrel is placed adjacent to the side of the triangle (left hand edge in the illustration above) and then it is tacked to the mandrel using a special iron to heat and melt the resin. Next, the graphite cloth is carefully and tightly rolled around the mandrel. Once all of the cloth has been rolled around the mandrel, a special type of heat resistant tape is carefully and tightly wrapped around the cloth to hold it in place. Next, the steel mandrel with the graphite cloth and tape wrapped around it is hung tip down from a large rack along with several other mandrels and then the rack is rolled into a large oven. Next, the temperature of the oven is slowly brought up to the point where it causes the resin in the graphite cloth to liquefy while the mandrel and the tape act as a mould. After the resin is liquefied, the oven is turned off and the resin is allowed to cool and harden. After the oven has cooled, the rack is removed and the steel mandrels are taken down and the tape is removed. Then, the mandrel with the graphite cloth still wrapped around it is placed in a special machine which removes the mandrel from inside of the graphite cloth leaving a hollow, tapered, graphite tube. Next, the hollow graphite tube is placed in a special sanding machine which very carefully sands the outside surface of the tube until it is smooth to remove the tape marks. Last, the hollow graphite tube is painted with a special type of paint and then the blank is placed in another special type of oven which then heats and hardens the paint; thus creating a finished graphite rod blank.

Once the finished rod blank is created, it is passed along to a rod builder who then assembles the various components to create a finished fly rod. In order to do this, the rod builder must first find and mark the rod blank's spine which is the place on the inside of the hollow graphite tube where the edge of the graphite cloth was originally tacked to the mandrel. This edge creates a line down the inside of the hollow rod blank which is slightly stiffer than the rest of the blank. The reason that finding the spine is important is that when the rod blank is bent (loaded) during casting, the hollow tube is inclined to twist ever so slightly to one side or the other because one side is stiffer than the other side and if the guide are not placed on the blank correctly, it can adversely affect the accuracy of the cast. In order to find this spine, the rod builder uses a special tool called a "spine finder" which consists of a hollow plastic tube with a ring of ball bearings encased between two steel rings placed at each end (see illustration).

Thus, each section of the rod blank is inserted into the spine finder and gently bent which causes the rod blank to rotate in such a way that the spine moves to the bottom side of the bend because the spine is slightly stiffer than the rest of the hollow tube and thus is stretches less when the blank is bent. Once the spine is found, it is marked for future reference.

Next, the rod builder assembles the sections of the blank and determines how far in front of the grip he wants to place the stripping guide. Then, he measures the distance from the stripping guide to the tip of the rod and uses a formula based upon the distance from the stripping guide to the tip of the rod blank and the total number of guides to be applied to determine the exact placement of each guide. Next, the rod builder starts with the tip section of the rod and proceeds to precisely place each guide in the correct position along the blank on the side opposite the spine and then uses either masking tape or hot melt glue to temporarily hold the guide in place. Once all of the guides are correctly placed along the length of blank and temporarily secured, the rod builder performs a "static deflection test" to be certain that the each guide is placed correctly. To perform this static deflection test, the assembled sections of the blank are placed back into the spine finder and a piece of string is run through all of the guides and then pulled tight; thus causing the rod to bend as it would when an angler is fighting a fish. This allows the rod builder to note any sections of the blank where the rod is not bending smoothly and to adjust the placement of the guides accordingly to correct the problem. Once the placement of the guides has been tested and adjusted if need be, the blank is then placed in a special jig and the guide's feet are wrapped in place using a special type of thread to secure them to the rod blank.

Once all of the guides on the top sections of the rod have been wrapped in place, work can begin on the bottom section of the blank. The first step in assembling the bottom section of the rod is to attach the reel seat. In order to do this, the diameter of the blank must first be built up to match the inside diameter of the reel seat. Thus, an arbor is secured to the blank which can be made of graphite, cork, or masking tape rings. Then the reel seat is slid onto the arbor and left in place temporarily. Next, a cork grip is selected and, using a special tapered reamer, the hole through the center of the grip is reamed out to match the size of the bank onto which it is being fitted so that it will fit tightly when slide down the blank and over the end of the reel seat. Then, the stripping guide is wrapped into place in the correct position. After the stripping guide is secured to the blank, the reel seat is removed, epoxy is applied to the arbor and the section of the blank where the grip is to be placed and the reel seat is slid back onto the arbor and rotated so that it matches up with the stripping guide. Then the grip is slid back down the blank and over the end of the reel seat and the epoxy is allowed to cure.

Once the bottom section of the rod is assembled and all of the guides are wrapped into place, the rod builder next applies a coat of special epoxy to the wraps on each of the guides and allows it to cure thus finishing the rod. Last, the length of the rod and line weight it is designed for are marked on the blank above the grip and a coat of epoxy is applied over these markings and allowed to cure. Once this last step is complete, the rod is ready for the fisherman to use.

Thus, as you can see, there are many intricate steps involved in making a graphite fly rod and the care with which each step is done, along with the quality of the materials involved, determines both the quality and the cost of the finished fly rod. Therefore, the old adage "you get what you pay for" definitely applies to graphite fly rods and in my experience, inferior equipment provides an inferior experience. Thus, whenever you are shopping for a new graphite fly rod, I would strongly suggest that you purchase your new rod from a reputable manufacturer or custom rod builder and that you purchase the best rod that you can afford.

Bill Bernhardt

Instructor & Guide

Harper Creek Fly Fishing Company

Why Hire A Fly Fishing Guide?

I was having a conversation with an acquaintance the other day who told me that he was planning a vacation to an area where there are some great opportunities for fly fishing. So, I asked him if he intended to hire a guide? However, my friend apparently thought this was unnecessary since he replied: "I know how to cast and I know how to fly fish, why would I need to spend money on a guide?".

But, when heading off to unknown waters, it's often a very good idea to seek out a local guide for at least one of the days you will be fishing, even if you are a seasoned angler. Most guides want you to be successful and can put you on to the fish quickly with their local knowledge of the water and the fly patterns that are most commonly taken by their fish. In fact, they will often have their own "secrets" that you won't find on Internet forums and message boards. Plus, if you're a novice, a guide can help you with casting problems and should be able to teach you basic entomology and how to read water.

Not only that, a good fly fishing guide can help keep you safe. Many rivers and streams have their own dangerous areas and knowing where they are and how to deal with them is often something that can only come with intimate knowledge of a particular body of water. Thus, a guide can often prevent you from having a nasty fall that may end with broken gear. So, when you're speaking  with a guide with the intention of hiring him or her, be honest with them about your fly fishing experience. If you've only been out a few times, don't tell them you are an expert who can wade fast water or cast in tight quarters. It will only make for a frustrating day for both of you.

Also, be sure to ask your guide if they provide gear and if so, what type? In addition, will you need to bring along your own waders? What kind of waders does the guide recommend? Will they provide the flies and if so, is there an extra charge for that? What about lunch? Some guides will provide a lunch while others would prefer that you bring your own lunch. However, don't judge a guide by whether or not he provides lunch. Some guides are terrific on the river but just aren't that great in the kitchen.

Last, calling up fly shops that are local to where you want to fish can be a very good way of learning who is recommended in the area. Also, be sure to find out whether your guide is trained in basic first aid and let them know of any special medical requirements of physical restrictions you might have. With the two of you working together, you should have a great day, regardless of the conditions you are fishing in.

Bill Bernhardt

Instructor & Guide

Harper Creek Fly Fishing Company

Update @ Paint Rock Outfitters, Wyoming

Hey all,

Spoke with Paul out at Paintrock Outfitters, Big Horn Mountains of Wyoming, and he tells me he made it up to the lodge last week, snow was really deep, done some fishing, caught some great fish, and the ice on the lake was 4feet thick. So sounds like lots of fun. Anyway he also advises that he has 14 hunters for the upcoming season, and can handle up to 20+, so if you are interested in hunting the legendary Big Horn Mountains of Wyoming, then now is the time to contact him.

The mule deer and elk hunting is absolutely incredible, coupled with the best trout fishing in Wyoming, equals pure adrenaline. As an added bonus  you will not find a better group of people to take care you. The guide service and accomodations are second to none. Paint Rock  lodge is very comfortable, so forget roughing it in a tent, you have a nice bed to sleep in, and meals that are fit for royalty. So if you have not made your hunting plans give Paul a call or email him directly from their website.

Here at Select we are excited about the upcoming seasons and hope everyone bags the trophy of a lifetime. So whether, its big game, fresh water fly fishing for trout, or anything in between, check out select outfitters for the best directory of hunting outfitters, fishing guide services or if you just want to find a great campground, let us direct you to the source of your next outdoor adventure.

Thanks,

Doug Suttles

Select Outfitters

Wader Safety is something everyone should know

What frustrates me most about this story is that it could easily have been prevented. How you might ask? By the simple act of putting on a wader belt. That's all it would have taken in order for the fellow to have had a fighting chance at swimming out of the creek instead of drowning in it! Now, please understand that I am not suggesting that you only wear waist-height waders instead because I too often wear chest waders on the very same section of the same stream where the fellow drowned. But, being aware of the danger, I always wear a wader belt. While most chest waders come with a wader belt, some may not and thus any nylon belt will serve the purpose which is to prevent water from filling your waders past a certain point. So, although a wader belt will not prevent water from entering the top of your waders, it will prevent or at least drastically slow the advance of water into the section below the belt. Thus, giving you a chance to swim to safety. So, if you have a wader belt, then wear it every time you put your waders on and if you don't have one, then visit your local fly shop and purchase one. I may very well save your life.
To view more articles of this nature, as well as articles on the various trout species found in western North Carolina, in addition to articles on general and specific fly fishing knowledge, visit www.nc-flyfishing.com where our goal is to provide you with the knowledge and skills you need to make you a more successful fly fisherman.

Bill Bernhardt
Instructor & Guide
Harper Creek Fly Fishing Company

Welcome William Bernhardt to Select Outfitters

We are pleased to announce that we  here at Select Outfitters have a new article writer . His name is  William Bernhardt he will author some Fly Fishing articles, about techniques, rods, reels, along with a whole host of other important viewpoints about fly fishing. He is a expert in the field of Fly Fishing and has provided a small biograpy about himself, so thought we would share that info with you, here it is, and we look forward to the upcoming articles. We are also building Mr. Bernhardt a website that will surely be a very valuable resource for him as well any one wanting to learn more about Fly Fishing,.

About William Bernhardt

I was born in 1960 in small town called Lenoir (named after Confederate General William Lenoir) which is located in western North Carolina in the foothills of the Appalachian Mountains and on the eastern face of the Continental Divide. In addition, my father, who spent most of his life working for the U.S. Forest Service, was an avid outdoorsman and conservationist and he instilled in me from an early age both, his values and his love of the outdoors. Then, at age eight, and after watching my father fly fish for several years when we camped on Slick Rock creek, I convinced him to buy me my first fly fishing outfit and I have been obsessed with the sport ever since.

Furthermore, due to my father’s employment with the U.S. Forest Service, I have lived and fished in some of the most exotic locations the U.S. has to offer. Such as: Juneau, Alaska, Jackson Hole, Wyoming, and Marathon, Florida which is located in the Florida Keys. But, although my fishing experience is widely varied, it wasn’t until I moved back to North Carolina and discovered the awe inspiring beauty and the profound sense of mystery and isolation that mountain streams offer the fly fisherman that I found my true love in life. Thus, I now consider myself a dedicated small-stream specialist. While I do still enjoy fishing larger streams for big Browns and Smallmouth Bass as well as kayak fishing on reservoirs for trout and smallmouth, plus the occasional trip on saltwater, I find myself returning over and over again to those hidden mountain gems where I very seldom see another person and the sense of discovery is always just around the next bend.

In fact, it was my love of “trout hunting” on small, mountain streams that first lead me to consider the idea of becoming a fly fishing instructor and guide and my first trip as a guide convinced me that teaching others about the sport of fly fishing was something that I was truly meant to do with my life. Since then, I have spent countless hours fly fishing on the small, mountain streams that have given me a profound understanding of the trout's environment and has led me to many observations about trout behavior that are not recorded in any book.

Last, it is very important for every fisherman to understand that trout are a precious resource and that their habitat is fragile. Thus, I now consider every angler that I teach to be a potential conservationist and I strongly urge each of them to join and become active in their local chapter of Trout Unlimited.