First time making a carbontex drag washer

[Decker]

Thanks, Jason. Starting to think maybe I need to find and buy the punches. Outer diameter is 24mm and inner is 15mm. I know time is precious.   

[oc1]

If you cut them with scissors, it may be a little ragged around the edges. But once they are greased and installed you will not be able to tell the difference in performance.  You can use a small chisel to get the ID hole started.

[JasonGotaProblem]

The mayhew set I inherited (RIP Keith) are pretty pricy. There appear to be much cheaper versions though if you search "hollow punch"
https://a.co/d/2Xeb3hX

I could do that size. The ID would have to be 16mm as my punches come in even number mm increments.

[Decker]

The mayhew set I inherited (RIP Keith) are pretty pricy.

Keith as in "Handi2"?   

[JasonGotaProblem]

The mayhew set I inherited (RIP Keith) are pretty pricy.

Keith as in "Handi2"?   

Yes indeed. The man, the myth, the legend.

[steelfish]

A keyed washer needs to fit the sleeve well in its center, but does an eared washer need to closely fit the sleeve, or do the ears only need to fit the slots?  I ask because I currently have Ultimate Penn 114 eared washers that could be made to fit inside the 50H main gear, but their center hole is substantially larger than the Daiwa sleeve. Hoping I can use the eared washers from the kit because they are wicked thin.

it should be no problem using those eared washers even if the center hole is bigger than the shaft sleeve, I have seen few factory drag setups with the eared metal washer like that, on quick search I found one example for that, the drag setup of the Okuma Komodo reel, look a that eared washer center hole and check the keyed metal washer center hole, a lot of difference, right? thats similar to what you can achieve with your DIY 5+1 drag kit.
so, work on those UU 114 eared washers and make them fit the 50H main gear

[Decker]

The mayhew set I inherited (RIP Keith) are pretty pricy.

Keith as in "Handi2"?   

Yes indeed. The man, the myth, the legend.

Wow, how long ago did he pass?  Seems like it wasn't long ago that he got married.

[Decker]

Alex, thanks for answering the question. I'll definitely use the UU eared washers then.  Yes, the pic illustrates the situation.

[JasonGotaProblem]

The mayhew set I inherited (RIP Keith) are pretty pricy.

Keith as in "Handi2"?   

Yes indeed. The man, the myth, the legend.

Wow, how long ago did he pass?  Seems like it wasn't long ago that he got married.

April 2023. There's a few threads worth reading if you wanna get the full story.

[day0ne]

Just rough them out or buy oversized diameter from Dawn, then clamp them between two keyed (not eared) washers with vice grips and hit them with a sanding drum on a Dremmel. I recommend a mask, but it only takes 15 or 20 seconds. Been doing it this way for ever.

[Keta]

Here is how I do it.  First a safety warning, CF dust is not good for your lungs so use a vacuum cleaner for dust control.

Start by laying out where you are going to cut.
Drill a pilot hole in the CF

Grind the ears off of 2 eared washers and clamp them on both sides of the  rough cut CF

Using the hole in the metal washer as a guide grind the CF with a Dremel for the center hole

Bolt through the hole holding the metal washers tight to the CF and shape the outside on my belt sander

The final product comes out perfict.

[Gfish]

A good way to start with the OD is a pair of heavy-duty tinsnips. Then the sanding. USE A MASK.

[Decker]

Thanks, all, Alex, Jason, David, Lee, Greg, Steve!  It takes a village to educate this crazy reel customization dilettante (me ). 

I like the simplicity of the latest suggestions, to cut the Carbontex roughly and shape by sanding.  I think I can live with that and avoid buying tools or delegating tasks at holiday time to other fathers and husbands.

The only unsolved part of this 5-stack design is the keyed washers.  The 3-stack I am replacing came with two Daiwa stainless keyed washers of different thicknesses, 1.9 and 1.4mm.  In my thickness total, I counted on using three of the 1.4mm keyed washers, but have only the one.  Worst case, I can open up a couple of other Sealine reels to find that washer, and harvest there, though that may cripple other reels. To make it more challenging, the two thicknesses seem to have the same part number 376-3401 "drag washer B". So even if I buy additional washers, I can't be sure to get the thinner ones. I asked two eBay sellers to put a caliper on them, and crickets... 

Any other ideas for the keyed washers? Anyone on this site have a trove of Daiwa Sealine parts? I thought of grinding down thick ones, but only have an orbital sander to help with that. 

Cheers!
     

[JasonGotaProblem]

Speaking of calipers. What's the width of the round part and width of the flat part? Also what is the height of the stock drag stack? I've got a few ideas but I don't wanna blurt them out til I've done the sniff test.

[Decker]

Speaking of calipers. What's the width of the round part and width of the flat part? Also what is the height of the stock drag stack? I've got a few ideas but I don't wanna blurt them out til I've done the sniff test.

Hey Jason,

• The hole of the stock keyed washer is 12.5mm on the round dimension and 10.0mm on the flat dimension.
• The original stack is 8.8mm.

I think I may have found what I need on the web! Emailed Andy at TunasReelTroubles.com (https://stores.tunasreeltroubles.com/)and he has the keyed washers in the right thickness.  Also, he sells carbon disks in various outer diameters and thicknesses. They need the ID drilled. $4 a disk but this might just do it!    I love DIY, but "get her done" takes precedence.