Well this is disappointing. Cracked brake on Lews BB.

[Loganberry]

On the Texas Gulf Coast we used to call that style a "popping rod"

Bass Pro has it labeled as a pitching rod for thick weeds and pads. It's quite a bit heavier than a typical medium or medium heavy large mouth bass rod. I don't pitch bass lures but it will work great for heavier freshwater jig heads or in current. It has tons of Fuji guides.

[jurelometer]

I know nothing about 3-D printing other than there is such a thing.  A possibility, maybe?

Not too tricky to print, you would have to salvage and reuse the metal parts, and also maybe design and print a fixture to set the pins properly.  But the the time spent measuring, drawing, printing a couple iterations to get it right ain't going to be worth it it for a single reel unless you are excited about the challenge.

There is going to be very little load on that part.  It probably failed due to stresses from the original injection molding  and/or the expansion difference between the metal ring and the plastic.  A repair might hold ok, but it has to be well aligned and balanced to be useful.  I wouldn't use staples.

A trick to consider is heating some tiny pins cut from a sewing pin and setting them into the parts before melt welding.  This is a trick that I use occasionally when assembling thermoformed plastic parts.  A hot (but not red hot) pin will go right in and then lock a bit as the pin cools, maintaining alignment for welding and adding some shear strength. 

You also might want to try the reel without the brake.  It might not be too bad, maybe even better if you like casting light lures and have a good thumb.

-J

[Loganberry]

I know nothing about 3-D printing other than there is such a thing.  A possibility, maybe?

Yes. The tolerance of weight distribution is going to be zilch. I have it epoxied up but even the weight of the epoxy will likely affect casting. Still have to set the last pin. We'll see how it goes but really the brakeless option is probably a better one.
Not too tricky to print, you would have to salvage and reuse the metal parts, and also maybe design and print a fixture to set the pins properly.  But the the time spent measuring, drawing, printing a couple iterations to get it right ain't going to be worth it it for a single reel unless you are excited about the challenge.

There is going to be very little load on that part.  It probably failed due to stresses from the original injection molding  and/or the expansion difference between the metal ring and the plastic.  A repair might hold ok, but it has to be well aligned and balanced to be useful.  I wouldn't use staples.

A trick to consider is heating some tiny pins cut from a sewing pin and setting them into the parts before melt welding.  This is a trick that I use occasionally when assembling thermoformed plastic parts.  A hot (but not red hot) pin will go right in and then lock a bit as the pin cools, maintaining alignment for welding and adding some shear strength. 

You also might want to try the reel without the brake.  It might not be too bad, maybe even better if you like casting light lures and have a good thumb.

-J

Yes. Even the epoxy I used will probably negatively affect the balance. Still have to set the last pin and we'll see how it goes.

[Keta]

The part appears to be available.  Item #91


https://lews.zendesk.com/hc/en-us/sections/4411516029719-Casting

[Loganberry]

The part appears to be available.  Item #91


https://lews.zendesk.com/hc/en-us/sections/4411516029719-Casting

I appreciate it, Keta, but these are for more modern reels. This is a BB61 which doesn't seem to be available. Not quite the same brake or surrounding parts, unfortunately.

[JasonGotaProblem]

Does it have a mag brake? If this setup fails the removal of that brake plate probably makes room for some magging