| Fly-Rod Making -- Preparing Bamboo Strips |
From "The Outdoor Zone"
episode TOZ-102 |
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In this segment, expert fly-rod craftsman John Cole begins the process of creating a hand-made bamboo fly-rod by splitting and preparing the basic material -- bamboo strips. The rod made in this demonstration is a two-piece rod -- a butt section and tip. The steps shown in the episode are only those used to make a single tip section, since the process is very similar for each of the sections. A third section -- a spare tip -- is also made as part of the complete process. Fly-Rod Making -- Preparing Bamboo Strips
- Safety Alert: Always wear eye protection, and follow safety precautions, when using a torch or any power tools.
- The first step in the process is to split the bamboo shaft into two halves using a splitting tool and mallet (figure A).
- Part of the natural beauty and uniqueness of a hand-made rod is in its coloration. Part of that attribute is established early in the process by flaming the surface of the bamboo to create a darkened and variegated pattern. With bamboo split lengthwise into halves, a torch is used to flame the surface (figure B), adding color to the blond bamboo. Only the tip of the flame is allowed to touch the bamboo surface. Aside from its aesthetic use, flaming serves to remove any moisture that may be remaining in the reed.
- After flaming, the bamboo halves are turned over, and the nodes that divide the inside of the reed are removed using a gouge and mallet (figure C).
- After gouging, the bamboo halves are split into narrower sections (figure D). The goal is to end up with six strips that will ultimately be used to make up one of the sections of the fly-rod. (A total of 18 strips are ultimately needed to make the butt section, tip and spare tip.)
- Once the six narrow strips are divided, they are laid out so that the nodes are staggered. Placing nodes adjacent to each other in the finished rod could create weak points. To ensure that the nodes are not collected along the same spot on the rod, Cole makes sure that the nodes are placed 8 inches apart, and staggered (figure E).
- Once the pieces are laid out, excess length is cut off using a saw, creating a 45-inch overall length. This provides the material for a unified strip of bamboo that's long enough for the tip of the rod.
- The nodes create natural imperfections in the woody material of the bamboo. To flatten the nodes, a block plane is used on each strip and each node (figure F ) to ensure that each strip is smooth.
- After the block plane, a file is used to smooth the strips further. With both the block plane and file, care is taken not to damage the power fibers just below the surface of the bamboo. Cutting into these fibers would weaken the rod.
- The final step in removing the nodes is a heat treatment combined with compression. Each node is held over the heat gun for 2 to 3 minutes (figure G). Each strip is then quickly inserted into a vise, and the vise is tightened. The heat, combined with the compression of the vise and the previous steps, results in a strip with no bulging nodes.
- The six strips will ultimately be wrapped together and used to form the completed tip. To achieve the proper overall shape, each strip will need to be planed to a 60-degree angle. The six wrapped pieces will combine to form a 360-degree hexagonal rod (figure H).
- Planing is a three-step process that utilizes rough, intermediate and final planing-bars. The result, after final planing, will be six strips, each of which will have a perfect 60-degree cross-section.
- Starting with the rough planing bar, each strip is placed in the gap with the enamel side is touching the angled edge. The excess bamboo extending up above the bar's surface is planed away (figure I) until the bar and block-plane are flush and make contact.
- Progress is checked using a 60-degree gauge, ensuring that each strip is smooth and has the proper shape.
- Once all six strips have been planed in the rough planing bar, the process is repeated in the intermediate planing-bar (figure J), resulting in smaller strips that maintain the 60-degree triangle. Only two sides of each strip is planed, leaving the enamel side untouched.
In the segment that follows, the bamboo strips are given their final taper and prepared for binding.
RESOURCES :
The Complete Idiot's Guide to Fly Fishing
ISBN: 0028629531
Author: Michael D. Shook
The American Museum of Fly Fishing
Web site: www.amff.com
The Complete Book of Fly Fishing
Author: Tom McNally and Tom Beecham
GUESTS :
John Cole
John Cole is a solo craftsman who creates handmade bamboo fly-rods.
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