Reel Repair by Alan Tani

Conventional and Bait Casting Reel Rebuild Tutorials and Questions => Penn 99/Jigmaster/SurfMaster/Squidder Tutorials and Questions => Topic started by: Maxed Out on December 01, 2016, 02:08:08 AM

Title: Cortez Classic Jigmaster
Post by: Maxed Out on December 01, 2016, 02:08:08 AM
  It was a crappy, stormy, cold rainy day until my postman showed up at my door today. upon opening the box from Cortez Conversions, it went from cloudy day to sunshine !! How can anyone ask for more. Fantastic job Tom did on these classic jigmasters. A true piece of modern art.

  This one has all Alan C's internal upgrades and everything slid right in and operates smooth as silk !!

P.S. nothing wrong with Toms black tongue and clamp, but on this one the silver theme was on my mind. ;D
Title: Re: Cortez Classic Jigmaster
Post by: Rothmar2 on December 01, 2016, 02:17:18 AM
Stunning!!!
Wish I could afford a kit.
Title: Re: Cortez Classic Jigmaster
Post by: STRIPER LOU on December 01, 2016, 02:54:18 AM
Awesome job Ted! Colors are perfect!
............... Lou
Title: Re: Cortez Classic Jigmaster
Post by: twotone on December 01, 2016, 03:01:40 AM
Nice head turner.
Title: Re: Cortez Classic Jigmaster
Post by: mo65 on December 01, 2016, 03:10:53 AM
:o Good Goobly Woo :o
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 01, 2016, 03:25:40 AM

Same 99 with partnered with black. I feel like a kid in a candy store......guilty as charged :D :D

 
Title: Re: Cortez Classic Jigmaster
Post by: Alto Mare on December 01, 2016, 03:41:01 AM
Awesome as always. Ted, both look good, but that handle on top really makes it.
Title: Re: Cortez Classic Jigmaster
Post by: Bill B on December 01, 2016, 04:28:52 AM
Seriously Cool Beans.....love the blue color.....Bill
Title: Re: Cortez Classic Jigmaster
Post by: Bryan Young on December 01, 2016, 05:01:31 AM
Holy Cannoli. That's good stuff right there.
Title: Re: Cortez Classic Jigmaster
Post by: steelhead_killer on December 01, 2016, 05:18:38 AM
W O W  ummm  W O W stunning combination of colors!  Great job!

Andy
Title: Re: Cortez Classic Jigmaster
Post by: Cortez_Conversions on December 03, 2016, 01:29:57 AM
Thanks for posting such great pics Ted. ;D
I really struggle with time and Photobucket!
Title: Re: Cortez Classic Jigmaster
Post by: Shark Hunter on December 03, 2016, 02:50:54 AM
Wow! :o
Title: Re: Cortez Classic Jigmaster
Post by: Swami805 on December 03, 2016, 03:57:42 AM
Very impressive Ted, My blue 99 came yesterday, beautiful work. Anyone know if an accurate spool will fit in it? Thanks Sheridan
Title: Re: Cortez Classic Jigmaster
Post by: Dominick on December 03, 2016, 04:06:01 AM
Holy cannoli is right.  Ted, how do you do it?  (rethorical)  :D Dominick
Title: Re: Cortez Classic Jigmaster
Post by: Vintage Offshore Tackle on December 03, 2016, 06:28:35 AM
Quote from: Swami805 on December 03, 2016, 03:57:42 AM
Very impressive Ted, My blue 99 came yesterday, beautiful work. Anyone know if an accurate spool will fit in it? Thanks Sheridan

It should Sheridan.  If you do not have one, let me know. 

Randy
Title: Re: Cortez Classic Jigmaster
Post by: Yogi_fish808 on December 03, 2016, 08:55:35 AM
Wow Ted!!
I wasn't sure how I felt about those but I've been swayed...that blue jigmaster is beautiful, awesome job as always! It's cold and stormy here in Honolulu too....it might dip into the low 70s tonight and rain, hahaha!
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 04, 2016, 04:03:19 AM
I have silver red and blue and they're all things of beauty. Hopefully a few other members will post their builds.

  Here is the silver 99 with newell spool and Alan C's eva knob.
Title: Re: Cortez Classic Jigmaster
Post by: Bryan Young on December 04, 2016, 04:14:06 AM
What is that eccentric Jack lever?
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 04, 2016, 04:35:33 AM
 
  Good eye Bryan, that's an experimental lever from my dungeon  :D :D
Title: Re: Cortez Classic Jigmaster
Post by: basto on December 04, 2016, 07:35:00 AM
Hi guys
Just wondering why they are called jig masters. Do they have a 500 drag?
Basto
Title: Re: Cortez Classic Jigmaster
Post by: Ron Jones on December 04, 2016, 09:00:37 AM
They are Jigmasters. They are just 99 width.
Ron
Title: Re: Cortez Classic Jigmaster
Post by: twotone on December 04, 2016, 06:23:28 PM
Wow Ted those levers look awesome. Will they be available?
Need a few. They would look great on any reel.
Title: Re: Cortez Classic Jigmaster
Post by: Islandgypsy on December 04, 2016, 07:36:42 PM
I'd also be in for several of those levers, Ted. Very nice, and practical for the arthritic thumb. Greg
Title: Re: Cortez Classic Jigmaster
Post by: twotone on December 04, 2016, 09:36:28 PM
(http://i1159.photobucket.com/albums/p633/doen1/Reel/20161204_115823_zpstgbxu9n1.jpg) (http://s1159.photobucket.com/user/doen1/media/Reel/20161204_115823_zpstgbxu9n1.jpg.html)(http://i1159.photobucket.com/albums/p633/doen1/Reel/20161204_120924_zpsoyn31vfm.jpg) (http://s1159.photobucket.com/user/doen1/media/Reel/20161204_120924_zpsoyn31vfm.jpg.html)

Tom's 99 Blacken/Blue kit, the 99 SliverBeach and a 500 JM Kit. I was lucky enough to get the 500 from Tom's previous round of kits.

The 24-5000 lever was cut to fit the sleeve with a fitted A.C. 45mm EVA knob installed.

Ted, I hope you'll make some shift levers Black and others colors too ?!!!

Nice work Tom!!


Title: Re: Cortez Classic Jigmaster
Post by: thorhammer on December 04, 2016, 09:45:12 PM
This is some sexy stuff. Nice builds folks. Keep'em coming. I cant open mine until Christmas!!!! :(
Title: Re: Cortez Classic Jigmaster
Post by: steelhead_killer on December 04, 2016, 10:14:54 PM
Need more eccentric lever information please.  ;D :o 8)
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 04, 2016, 10:29:42 PM
Quote from: steelhead_killer on December 04, 2016, 10:14:54 PM
Need more eccentric lever information please.  ;D :o 8)

  hi Andy, the lever shown is prototype. The one in production will have double O-rings (levers grooved to hold the o rings in place). It will be anodized in red,silver,blue,green,and black. First batch is going to plater this week, so hope to have em redy before Christmas. I'm shooting for $15 price, but will have exact price after anodizing. They will for sure be less than $20 each.
Title: Re: Cortez Classic Jigmaster
Post by: mo65 on December 04, 2016, 11:17:12 PM
Another home run on that lever Ted...very nice! 8)
Title: Re: Cortez Classic Jigmaster
Post by: nelz on December 05, 2016, 03:06:13 AM
Quote from: basto on December 04, 2016, 07:35:00 AM
Hi guys
Just wondering why they are called jig masters. Do they have a 500 drag?
Basto

At this stage of inside & out hot-rodding, IMHO it they really are not Jigmasters any more. Gorgeous reels though!
Title: Re: Cortez Classic Jigmaster
Post by: twotone on December 05, 2016, 03:42:19 AM
 We can call them Galapagos reels. (Darwin's theory of evolution, Penn reels:)
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 05, 2016, 05:02:34 AM
internally they are 100% jigmaster, so yes they are still a jigmaster reel at heart.

Here is another Cortez Classic 99. Tom makes our builds look like a gem no matter how you slice it(or build it Lol)
Title: Re: Cortez Classic Jigmaster
Post by: twotone on December 05, 2016, 05:57:28 AM
Ted you're killing me, with that red 99.

You're proto type shift lever looks fantastic.

My messed up right hand, is gonna like your eccentric lever.

There almost close to a lever drag. Can't wait to see!

Ted did you get that handle and knob from Randy Pauly?
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 05, 2016, 05:49:08 PM
Quote from: Islandgypsy on December 04, 2016, 07:36:42 PM
I'd also be in for several of those levers, Ted. Very nice, and practical for the arthritic thumb. Greg


 No problem Greg, I'll give you a shout when they're back from the plater in next couple weeks


 Anthony, Black will be one of the lever colors, and of course that handle came from Randy Pauly  :D :D
Title: Re: Cortez Classic Jigmaster
Post by: STRIPER LOU on December 05, 2016, 06:14:05 PM
Ted, the reel is awesome! 
Please put me on the list for several of those great looking eccentric's. Nice work.  ;)
Title: Re: Cortez Classic Jigmaster
Post by: steelhead_killer on December 05, 2016, 09:10:43 PM
Top Shelf!

Quote from: Maxed Out on December 05, 2016, 05:02:34 AM
internally they are 100% jigmaster, so yes they are still a jigmaster reel at heart.

Here is another Cortez Classic 99. Tom makes our builds look like a gem no matter how you slice it(or build it Lol)
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 05, 2016, 11:39:28 PM
Quote from: STRIPER LOU on December 05, 2016, 06:14:05 PM
Ted, the reel is awesome! 
Please put me on the list for several of those great looking eccentric's. Nice work.  ;)


You were already on the list Lou. I figured I didn't need to ask Lol  :D :D


  There will be a clearance issue for offset handle arms. the next batch will have shorter top bar and thinner main body to allow more room for offset handle arms.

  Here is clearance with straight blade handle arm
Title: Re: Cortez Classic Jigmaster
Post by: Tightlines667 on December 06, 2016, 03:32:53 AM
I like 'em Ted!

They loook sharp, and should improve function, as well as preventing wear issues.  No chance of fumbling around trying to find that lever in the heat of the moment. 

Keep up the great work!
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 06, 2016, 06:36:28 PM

  Nobody has posted a 501 Cortez classic yet, I know I'm not the only one building Toms kits, so c'mon and post em up, we want to see them.

  Here is my version of the classic 501, and  99, and a soon to be built 500
Title: Re: Cortez Classic Jigmaster
Post by: steelhead_killer on December 06, 2016, 07:23:18 PM
Beautiful Set!  Damn those are hot!

Quote from: Maxed Out on December 06, 2016, 06:36:28 PM

  Nobody has posted a 501 Cortez classic yet, I know I'm not the only one building Toms kits, so c'mon and post em up, we want to see them.

  Here is my version of the classic 501, and  99, and a soon to be built 500
Title: Re: Cortez Classic Jigmaster
Post by: Larosha on December 06, 2016, 10:35:35 PM
Just finished mine yesterday.
I was looking around for a stainless handle but couldn't find one.
That prototype eccentric lever looks great though I'd buy one haha.
Cortez kit, Pro Challenger SS parts, Brian's 5+1 drags and an EVA knob.
Title: Re: Cortez Classic Jigmaster
Post by: spc7669 on December 06, 2016, 11:06:28 PM
If you make those levers for a 113H I'm good for three.
Thanks
Patrick
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 06, 2016, 11:09:19 PM
Quote from: Larosha on December 06, 2016, 10:35:35 PM
Just finished mine yesterday.
I was looking around for a stainless handle but couldn't find one.
That prototype eccentric lever looks great though I'd buy one haha.
Cortez kit, Pro Challenger SS parts, Brian's 5+1 drags and an EVA knob.



  Very nice combo and great first post. Welcome to the forum. Sounds like you've already been hanging out if you have all those internals in your classic Jigmaster.

  Custom levers will be ready very soon, and very affordable. If you're looking for custom handle arms then Adam is your guy, and for custom knobs its Lou, or Alan C.

  -Ted
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 06, 2016, 11:11:50 PM
Quote from: spc7669 on December 06, 2016, 11:06:28 PM
If you make those levers for a 113H I'm good for three.
Thanks
Patrick


 Hi Patrick, These levers are direct replacement for Penn #66 lever, so it is the correct lever for jigmaster as well as any 4/0 and any other penn that takes #66 lever. The first batch of 100 is in my hands, just gotta get them to the plater. Waiting for break in the weather to make the 5 hour drive

 -Ted
Title: Re: Cortez Classic Jigmaster
Post by: spc7669 on December 06, 2016, 11:19:51 PM
Thanks Ted! Can't wait till they're available.
Title: Re: Cortez Classic Jigmaster
Post by: Larosha on December 07, 2016, 10:07:16 AM
Quote from: Maxed Out on December 06, 2016, 11:09:19 PM
Quote from: Larosha on December 06, 2016, 10:35:35 PM
Just finished mine yesterday.
I was looking around for a stainless handle but couldn't find one.
That prototype eccentric lever looks great though I'd buy one haha.
Cortez kit, Pro Challenger SS parts, Brian's 5+1 drags and an EVA knob.



  Very nice combo and great first post. Welcome to the forum. Sounds like you've already been hanging out if you have all those internals in your classic Jigmaster.

  Custom levers will be ready very soon, and very affordable. If you're looking for custom handle arms then Adam is your guy, and for custom knobs its Lou, or Alan C.

  -Ted


Thanks! All I wanted was 5:1 gears and a non counter weighted handle then I snooped around this site and all of this happened haha.
Title: Re: Cortez Classic Jigmaster
Post by: Larosha on December 07, 2016, 10:12:07 AM
Does anyone have a solution to this?
My stock spacing sleeve has too much space between it and the plate. The one I got from pro challenger is maybe a MM too think. I really don't want to get sand in this reel.
Title: Re: Cortez Classic Jigmaster
Post by: Shark Hunter on December 08, 2016, 01:37:58 AM
You are going to have to sand it down to fit.
On Page 7, Sal shows you how its done.
http://alantani.com/index.php?topic=16099.90
Title: Re: Cortez Classic Jigmaster
Post by: Larosha on December 10, 2016, 01:02:48 PM
First field test with the reel was a success.
The fish couldn't pull drag on the strike and these fish usually have a violent initial run. I can't remember how tight I had the drag but I'm sure I didn't lock it all the way down.
Hawaiian lady fish or Awaawa. I think the fish weighed a good 4 lbs, no match for the setup apparently haha.
Title: Re: Cortez Classic Jigmaster
Post by: BryanC on December 10, 2016, 02:24:17 PM
Quote from: Larosha on December 07, 2016, 10:12:07 AM
Does anyone have a solution to this?
My stock spacing sleeve has too much space between it and the plate. The one I got from pro challenger is maybe a MM too think. I really don't want to get sand in this reel.


I made my own spacers out of 316SS tubing, and I'm happy with them.  Here's a link:
http://alantani.com/index.php?topic=16596.0
Title: Re: Cortez Classic Jigmaster
Post by: BryanC on December 10, 2016, 02:32:31 PM
The spacers I made were for the other Cortez plates - the ones that fit onto stock/Tiburon/Accurate frames.  I'm not sure if the gear sleeve hole diameter on the Cortez Classic right side plate is the same or not.  If you're thinking about doing this, it would be best to measure the hole ID before buying tubing.
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 10, 2016, 08:45:57 PM
 I know I'm not the only person building a Cortez Classic. Let's see some of those builds. :o :o

How can anyone resist ?? I sure can't. Here is another fresh built 501 ready to chase albacore.

Title: Re: Cortez Classic Jigmaster
Post by: Alto Mare on December 10, 2016, 08:51:52 PM
What do you expect? You're intimidating everyone with your awesome builds ;D.

Just as I suspected, that blue looks amazing with silver.

Very nice bud.

Sal
Title: Re: Cortez Classic Jigmaster
Post by: twotone on December 11, 2016, 04:17:59 PM
                My 501 Jiggy

                (http://i1159.photobucket.com/albums/p633/doen1/Reel/20161210_232553_zpsdwkbg8yi.jpg) (http://s1159.photobucket.com/user/doen1/media/Reel/20161210_232553_zpsdwkbg8yi.jpg.html)
                 


Title: Re: Cortez Classic Jigmaster
Post by: steelhead_killer on December 11, 2016, 04:38:12 PM
Silver/blue is my next build.  Just sings!  How do you like that large EVA knob? 

Andy

Quote from: Maxed Out on December 10, 2016, 08:45:57 PM
I know I'm not the only person building a Cortez Classic. Let's see some of those builds. :o :o

How can anyone resist ?? I sure can't. Here is another fresh built 501 ready to chase albacore.


Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 11, 2016, 06:20:36 PM
Quote from: steelhead_killer on December 11, 2016, 04:38:12 PM
Silver/blue is my next build.  Just sings!  How do you like that large EVA knob? 

Andy

Quote from: Maxed Out on December 10, 2016, 08:45:57 PM
I know I'm not the only person building a Cortez Classic. Let's see some of those builds. :o :o

How can anyone resist ?? I sure can't. Here is another fresh built 501 ready to chase albacore.



Andy, the eva knobs are perfect for the jigmaster and very comfortable in the hand.


Anthony, sweet reel,.... a silver shift lever will finish that reel off nicely. :o :o
Title: Re: Cortez Classic Jigmaster
Post by: twotone on December 11, 2016, 07:22:20 PM
Patiently waiting.
Title: Re: Cortez Classic Jigmaster
Post by: mo65 on December 11, 2016, 07:35:06 PM
Quote from: Alto Mare on December 10, 2016, 08:51:52 PM
What do you expect? You're intimidating everyone with your awesome builds ;D.

      That could be a possibility...Ted's builds are very impressive. Actually...my empty pockets are holding me back! :D
Title: Re: Cortez Classic Jigmaster
Post by: pompano joe on December 19, 2016, 01:55:22 AM
Still working through handle options.  Definitely want one the the eccentric levers from this thread!
Title: Re: Cortez Classic Jigmaster
Post by: steelhead_killer on December 19, 2016, 02:13:38 AM
Pompano Joe  that is a great set up.  Love the extra work on the drag star! 

Andy
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on December 19, 2016, 03:14:52 AM
Dear Mr Pompano ;D ;D say no more....your shifter will be ready soon and coming your way. Any particular color ??

  -Ted
Title: Re: Cortez Classic Jigmaster
Post by: pompano joe on January 16, 2017, 06:22:08 PM
Quote from: Maxed Out on December 06, 2016, 06:36:28 PM

 Nobody has posted a 501 Cortez classic yet, I know I'm not the only one building Toms kits, so c'mon and post em up, we want to see them.

 Here is my version of the classic 501, and  99, and a soon to be built 500

Just finished my shop's first Cortez Conversions build. "Blaze" is a Penn Jig Master Junior 501 at heart, but a complete custom otherwise.

The machined and red anodized aluminum frame and side plates are Cortez, the silver aluminum spool is a recent add to the PRO Challenger (PC) line. Inside it's got a PC stainless (SS) gear set, 5+1 Carbontex and SS drag set, SS pinion yoke and jack, SS gear sleeve and double dog bridge from PG, and custom drag star and off-set power handle from Motive Fabrication.

As always, special thanks to friend and reel mentor Keith Rawson. Also appreciate the guys at PRO Gear, Motive Fabrications and Cortez Conversions for their fine products amazing service.

Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on January 16, 2017, 07:05:47 PM

That's a beauty Joe. The new low profile shift levers will be ready in couple weeks and I'll make sure you get one for your classic jigmaster.

  -Ted
Title: Re: Cortez Classic Jigmaster
Post by: twotone on March 06, 2017, 03:39:58 AM
(http://i1159.photobucket.com/albums/p633/doen1/20170305_192354_zpsr1worq9e.jpg) (http://s1159.photobucket.com/user/doen1/media/20170305_192354_zpsr1worq9e.jpg.html)


Classic 501 update.


Thx Tom, R.P., Ted, Sal, Pennparts, and Alan c.



Title: Re: Cortez Classic Jigmaster
Post by: Bryan Young on March 06, 2017, 06:58:45 AM
Beautiful!
Title: Re: Cortez Classic Jigmaster
Post by: Shark Hunter on March 06, 2017, 07:28:12 AM
Very Nice tt. ;)
Title: Re: Cortez Classic Jigmaster
Post by: Maxed Out on March 06, 2017, 05:01:30 PM
Quote from: twotone on March 06, 2017, 03:39:58 AM
(http://i1159.photobucket.com/albums/p633/doen1/20170305_192354_zpsr1worq9e.jpg) (http://s1159.photobucket.com/user/doen1/media/20170305_192354_zpsr1worq9e.jpg.html)


Classic 501 update.


Thx Tom, R.P., Ted, Sal, Pennparts, and Alan c.





  Wow, that's a sweet build Anthony. How can you top that one ?? I know you'll somehow find a way !!

  -Ted
Title: Re: Cortez Classic Jigmaster
Post by: Cortez_Conversions on March 07, 2017, 02:33:23 AM
Thanks for sharing!
Title: Re: Cortez Classic Jigmaster
Post by: Benni3 on March 07, 2017, 02:37:20 AM
Sweet!!!
Title: Re: Cortez Classic Jigmaster
Post by: twotone on March 07, 2017, 03:21:03 AM
Thanks all !

I didn't mention Jay at Fishgrain (stock gear and pinion).

Thanks Jay!

Title: Re: Cortez Classic Jigmaster
Post by: Alto Mare on March 07, 2017, 03:24:36 AM
Beautiful reel!... love the classic.

Sal
Title: Re: Cortez Classic Jigmaster
Post by: pompano joe on April 25, 2017, 08:58:45 PM
The new low-pro eccentric lever worked perfectly, Maxed Out!  So thankful for you and all the guys who provide the cool parts for our obsession!


Quote from: Maxed Out on January 16, 2017, 07:05:47 PM

That's a beauty Joe. The new low profile shift levers will be ready in couple weeks and I'll make sure you get one for your classic jigmaster.

  -Ted
Title: Re: Cortez Classic Jigmaster
Post by: handi2 on April 25, 2017, 11:01:53 PM
Looks great Joe.

I will try to post some pictures of mine tomorrow.

Keith
Title: Re: Cortez Classic Jigmaster
Post by: thorhammer on April 26, 2017, 12:53:48 PM
I never get tired of looking at these...or building them...gonna get two more...
Title: Re: Cortez Classic Jigmaster
Post by: moondog371 on July 03, 2017, 12:02:21 AM
work of art! very nice!
Title: Re: Cortez Classic Jigmaster
Post by: Rancanfish on July 13, 2017, 09:18:04 PM
Oh yeah, someday I'll swing one.