I recently put together some "light tackle" Penn reels for my brother and Rob...they really like their Abu Garcia Ambassadeurs...and these little Monofil/Beachmaster/Baymaster reels fall right into the Abu 6500/7000 sizing. I loved the feel of the ones I made them, so I decided to make one for myself. I used plastic spools in these reels, as the plastic spool is very light and casts easily. I've been experimenting with plastic spools for a few years now, and have yet to see any failures. When properly set up, they seem to be very reliable, but if filled with tightly wrapped mono it's all over!
The modifications to this reel are mainly aesthetic and not meant to increase power. The Monofil series uses the #5-155 main gear, and there isn't any drag upgrade kit for this size gear. If I had a way to grind down metal washers, I could make a 5-stack set up, but I don't really see it as needed for what I expect from this reel. I did flatten the stock metal drag washers to improve performance a bit, and I used a #13-200 pinion as per Wai's recommendations. I also used a ss dog spring to get a little better "slap".
This first photo is the reel as received...pretty crusty...but most of the crud appears to be just dirt.
(https://live.staticflickr.com/65535/51799188584_9ec8f2c1c9_z.jpg) (https://flic.kr/p/2mVjo7m)
I only have simple tools and cleaning supplies, so on a project like this I find the best way to prepare the reel for being torn down is to give it a shower of WD-40. This loosens all the crud, and also treats the dried out side plates.
(https://live.staticflickr.com/65535/51798944518_5cfa395e55_z.jpg) (https://flic.kr/p/2mVi8yj)
Once opened you can see there is a little corrosion on the chrome...that will get a vinegar bath. There appears to be plenty of grease on the bridge, so you'd expect to see the main gear in great shape. The real world is full of surprises...
(https://live.staticflickr.com/65535/51799551090_d80ae319a6_z.jpg) (https://flic.kr/p/2mVmeSs)
Oddly enough, the pic on the left below is the gear as it came out of the reel. What's with the rust?? It's been debated on how globs of grease can hold water...I think this is what we're seeing here. The pic on the right is after I filed the back side of the gear. Most of the chromium plating is gone now, but I think as long as it only has a film of grease it will be fine. I'd prefer a nice NOS Moly coated main, maybe down the road.
(https://live.staticflickr.com/65535/51799551080_8c619e88cd_m.jpg) (https://flic.kr/p/2mVmeSh) (https://live.staticflickr.com/65535/51798817976_93416d1792_m.jpg) (https://flic.kr/p/2mVhtWy)
The green arrow points to the anti reverse dog...trapped in that dried out gummy grease. The shine on the grease is only WD-40, and that AR dog was stuck like chuck. Once again...another reason to be frugal with your grease. I prefer to only oil the dog.
(https://live.staticflickr.com/65535/51798817561_2b97c0d1a6_z.jpg) (https://flic.kr/p/2mVhtPp)
I opted for one of those eBay replacement handles on this project. Of coarse, the mounting hole on these fits Abu/Daiwa, so break out the files. It doesn't take long, and GO SLOW, you want this fitment tight.
(https://live.staticflickr.com/65535/51798817961_d0d431a292_z.jpg) (https://flic.kr/p/2mVhtWi)
The photo below shows the stock handle and star beside the replacement handle and star. Mystic lists the #10-60 star for the 27, but my reel had this tiny #10-180 star. I used the larger #10-60 drag star, and I bet you're wondering how that was possible with the "bent back" style handle. Read on grasshopper...;D
(https://live.staticflickr.com/65535/51799188434_acc26cd8ec_z.jpg) (https://flic.kr/p/2mVjo4L)
I use two large crescent wrenches to bend the arms of the star. I put tape on the jaws of the wrenches to keep from scarring the chrome on the star.
(https://live.staticflickr.com/65535/51798944318_6516fa0261_z.jpg) (https://flic.kr/p/2mVi8uS)
The red arrow points to a Sharpie mark on the star's arm...this is the point where the star's arm passes over the sideplate bearing. This is also the point where the two wrenches meet to make the bend. Bend Easy...it only needs a slight angle. Surprisingly, the chrome doesn't flake off much when doing this.
(https://live.staticflickr.com/65535/51799188339_f8fc26ed4c_z.jpg) (https://flic.kr/p/2mVjo38)
And here's the finished drag star...kinda cool eh?
(https://live.staticflickr.com/65535/51797873432_a3b1d8f571_z.jpg) (https://flic.kr/p/2mVcDaj)
This picture shows the alignment between the handle, star, and sideplate bearing.
(https://live.staticflickr.com/65535/51799188279_8639e2c963_z.jpg) (https://flic.kr/p/2mVjo26)
The metal drag washers for these reels are stamped, and are not flat. This presents options...you can face them all the same way for a faster action of the star...you can alternate them for a slower action of the star...or you can file them flat and get the best power from the set up. The photos below show a filed washer on the left, and that same washer lapped with fine sandpaper on the right. Some folks say this is a waste of time, but I've found it to add a pound or two of drag power.
(https://live.staticflickr.com/65535/51797873337_186c2c45c1_m.jpg) (https://flic.kr/p/2mVcD8F) (https://live.staticflickr.com/65535/51797873312_8017000a29_m.jpg) (https://flic.kr/p/2mVcD8f)
Here's all the nuggets, ready to reassemble. Did you notice the Fluid Hub bearing in the upper right corner? Some folks love these things...some hate them...I think it does add some more control to the spool speed.
(https://live.staticflickr.com/65535/51799550755_dfc577bacc_z.jpg) (https://flic.kr/p/2mVmeLF)
I spooled 'er up with 80lb. braid and a 40lb. mono topshot. Can't wait to catfish this little reel! 8)
(https://live.staticflickr.com/65535/51799188149_be5e35ff71_z.jpg) (https://flic.kr/p/2mVjnYR)
(https://live.staticflickr.com/65535/51799188099_de4a9866bc_z.jpg) (https://flic.kr/p/2mVjnXZ)
(https://live.staticflickr.com/65535/51797873232_41dbd816b8_z.jpg) (https://flic.kr/p/2mVcD6S)
Sweet job Mike, as usual, thanks for taking us along, really nice, cheers Don.
Professional work, as usual, Mike!
Like you, I also have a set of couple of "adjustable Metric Crescents" — just for these types of jobs.
Best, Fred
Great work, pal. I'm gonna hunch that the steel gear and carbon drag will, in general, produce more power in a stronger reel than a 6500's brass, 5:1 gear.
Quote from: thorhammer on January 04, 2022, 04:31:23 PM
Great work, pal. I'm gonna hunch that the steel gear and carbon drag will, in general, produce more power in a stronger reel than a 6500's brass, 5:1 gear.
Just going by the numbers, the 6500 will produce about the same power as the small Penns...
BUT...for how long? I've seen huge catfish caught on the Abu reels many times, but it does stress them hard. The size difference in gear teeth and pinions is significant here. Common sense says the Penn will take more punishment. Like you John, I'm giving the nod to the Penn.
Nice work! Do you do anything inside the fluid hub?
Quote from: PacRat on January 04, 2022, 05:13:55 PM
Nice work! Do you do anything inside the fluid hub?
It's interesting you asked that Mike, as I did replace the fluid. I'm not sure what is originally used in them, but it did appear to be a thicker oil. I flushed the inside with Paslode spray cleaner and blew it dry. I mixed CorrosionX HD with a little Super Lube grease to make a lube similar to what was already in the thing. With spool endplay adjusted exactly like a stock bearing, the Fluid Hub definitely applies more braking. 8)
Fred my metric cresent is much better than yours, ha haa, best hammer I have ever had, thanks again Mike, cheers Don.
UPDATE: I just saw a user manual on another thread, and it says the Fluid Hub comes with 30 weight motor oil. It says that heavier or lighter weights can be used to fine tune it to your preference.
Handsome little reel Mike ! The handle and star are eye catchers... it's got me thinking ,
Cool
Love that reel!
I don't fish the one plastic pool I have since it is Rose colored, and those appear to be rare. If fishing plastic (not Rose colored), would follow the original factory spec for 300/15 and not exceed 4.5 lbs drag (reducing the 0.5 lbs just to be on the 'safe" side).
No interest on your end for a chrome 29M-27 or 29M-100? Aside from the spin factor, shouldn't detract much from an aesthetics standpoint...
Another sweet job Mike.
Quote from: Porthos on January 05, 2022, 02:01:43 AM
No interest on your end for a chrome 29M-27 or 29M-100?
I have a 29L-100 waiting in the wings Wai...just in case my "plaster spool" ever implodes! :D
Cool! I recently got a 25 & 27 with dark maroon plastic spools. Lots of Beachmaster parts. Now I got some ideas for improvements. Thanks Sensei!
MOmeister!!!
WOW!!! Again you hit it out of the ballpark!!!!
Just what a creative mind and talented hands can do!!!!
And the curve on the slightly bent star matches EXACTLY the radius of the new handle. Impressive.
SIR! You do great work.
If you ever make it out to the West Coast, this reel would be PERFECT for our Rockfish and Ling Cod fishing.
Wayne
Thanks everyone!! 8)
Looks good, I have my green monofil displayed so I see it everyday. I was just trying to look up the past threads on narrowing these with a tib frame. Then you posted this. Very serendipitous.
Looks like I have a project to work on
Nick
Very nice small reel, perfect for so many applications, Heck of a job you did on that one!
very nice build sir! i also am inspired to freshen up the 180 i picked up recently. thanks for posting great post and pics