Rod building

Question
I am starting my first rod. I have a Tennessee handle I am going to install. How do I finish the butt section of the rod? I thought the cork handle would be closed off on one end. It looks like I need to fill in the hole on the butt side of the handle. How do I do this? Also I would guess that I need to cut the handle in half in order to get the rings on? (to hold the reel). Any help would be great.

Thanks a bunch.

Steve

Answer
Hi Steve,

Lets start with the butt end question.  There are a couple things you can do.  

The easiest is to leave a 1/4 inch gap between the end of the cork ring and the butt end of the blank (don't run the blank all the way to the end of the cork).  Now glue a piece of cork in that gap or hole.  They sell tapered plugs that you can glue in there.  Let it stick out beyond the face of the cork rings.  When the glue is dry, file off (or a disc sander if you have one) the excess cork plug and if you do it right you will never know that there was a plug in there.

Another option is a rubber butt cap on the end.  You may have to file a little shoulder on the last ring for it to fit on.

I have also done a few other fun things for people over the years.  You can take a flat bit like a Forester bit and created a round recess (1/16th or so) in the end cork.  In that recess, I have glued in all kinds of things like a penny from the year they were born.  I have glued in these neat enameled golf ball markers that have the persons college on it.  Or, if you go to an engraver like "Things Remembered" (probably in your local mall) they will put initials, names, retirement dates, etc, etc on a small brass or silver disc  for a few bucks. Glue it in place.  Then turn the rod end up and put epoxy rod finish over it and let it cure.

If the handle you have is pre-made and not separated, yes you will have to cut it and glue it back together on the rod.  Put a pencil mark across the joint so it will line up later.  Sand the joint down after it's all glued back together and you will never see it.

The beauty of cork is that it can be sanded and repaired like wood.  Use 120 grit for rough spots and down to 400 grit for final sanding.  Those 3M sanding sponges are great for rod handle work.

Happy rod building.  Warning... it's addictive!!!

Marc