Reel Repair by Alan Tani

Conventional and Bait Casting Reel Rebuild Tutorials and Questions => Penn Senator Tutorials and Questions => Topic started by: Three se7ens on March 14, 2015, 02:45:05 AM

Title: big boy senator inserts
Post by: Three se7ens on March 14, 2015, 02:45:05 AM
On request of Daron and a few others, Ive started working on an insert and drag kit for the big boy senators:  10/0, 12/0 and 14/0, 16/0.  Heres where Im at now:  3/4" thick 5052 aluminum for the insert, 7 each 1.2mm carbon fiber washers, and 6 each 1/16" stainless keyed washers, and a thick keyed washer on top to give the proper height for the drag stack.  The insert sits below the rim of the gear by 1/8" on the 14/0, but I dont think there is anything to gain by going taller with the insert.  I think aluminum is a better choice for the insert in this case because the quality of the cut will be better than in stainless, and it will cost less. These inserts are really pushing the limits of waterjet capability, and I dont think acceptable results are realistic in 3/4" stainless. 

The attached pictures shows the insert for a 14/0.  I designed these so that both the 14/0 and 12/0 sized inserts will take the same carbon fiber and metal washers.  The insert fr the 14/0 will have a larger od, and a thicker wall, as you can see in the picture.  The 12/0 has the same ID on the insert, but a smaller OD and thinner wall.  All of the components except the insert itself will be interchangeable between these sizes.

Based off Sals testing of the other inserts, I expect these to make around 100 lbs of drag when locked down.  Now whether the rest of the reel is capable of handling that is a different story.  But that does mean that at 50 lbs, the drag will still be exceptionally smooth, and not heavily stressed. 

Im looking at pricing these kits in the low $50 range , and will include the insert, metal and carbon fiber drag washers, and delrin washer(s).
Title: Re: big boy senator inserts
Post by: RowdyW on March 14, 2015, 02:56:57 AM
Do you have an ETA on the 6/0-9/0 inserts?
Title: Re: big boy senator inserts
Post by: Three se7ens on March 14, 2015, 03:00:54 AM
Quote from: RowdyW on March 14, 2015, 02:56:57 AM
Do you have an ETA on the 6/0-9/0 inserts?

Picked up parts from the cutter today, Ill have 8 sets available in a couple of days.  Also have another batch of 113H inserts as well.
Title: Re: big boy senator inserts
Post by: Bryan Young on March 14, 2015, 03:06:43 AM
Nice Adam
Title: Re: big boy senator inserts
Post by: Keta on March 14, 2015, 03:07:45 AM
WOW!
Title: Re: big boy senator inserts
Post by: Tightlines667 on March 14, 2015, 03:13:56 AM
Awesome!
This is some good stuff and is definately getting me a bit excited.  I like the design concept (w/interchangable washers), and think the little thicker walls, and aluminum, should help with heat dissipation.  There is still plenty of room on top for an extra CF, and delron washer.  This has potential.
Title: Re: big boy senator inserts
Post by: Shark Hunter on March 14, 2015, 04:03:29 AM
I am Glad you came through with these Adam. With Tom's ss Sleeves and these inserts. It is Ground Breaking. Fishing Stand up on the Beach. I don't think I could hold 100lbs of drag unless I was strapped to the bumper of my Truck. I really appreciate this, and I'm sure others do too.
That extra drag will make it a lot easier to turn a Monster.
Title: Re: big boy senator inserts
Post by: basto on March 14, 2015, 04:08:52 AM
Wow, 100 lbs of drag. Great achievement for a star drag reel.
Can you get a full aluminium frame for a 14/0?
Title: Re: big boy senator inserts
Post by: Tightlines667 on March 14, 2015, 04:11:57 AM
Quote from: basto on March 14, 2015, 04:08:52 AM
Wow, 100 lbs of drag. Great achievement for a star drag reel.
Can you get a full aluminium frame for a 14/0?

No, but what we really need is a solid stand, and 3 bars..in my opinion.

This reel should handle a smooth 40-50lbs of drag w/o issue though.
Title: Re: big boy senator inserts
Post by: ChileRelleno on March 14, 2015, 04:22:20 AM
Hmmmm...  After danged near getting taken off my feet a few times by that big Hammer, I don't think I want anymore drag.   :o

WTH am I saying!   ::)
Sign me up for a 12/0, I'll cough up the money somehow.

Title: Re: big boy senator inserts
Post by: Shark Hunter on March 14, 2015, 04:26:17 AM
We can load up on triple Whataburgers to Hold us Down! ;)
Title: Re: big boy senator inserts
Post by: Tightlines667 on March 14, 2015, 04:30:26 AM
Quote from: Shark Hunter on March 14, 2015, 04:26:17 AM
We can load up on triple Whataburgers to Hold us Down! ;)

I wish we had those in HI!

We do have rocket holders (swivel rod mounts), and safety leashes though.  Guys here often lock down the drags and fish 250lb+ mono on 14s, this is just what the doctor ordered.  :)
Title: Re: big boy senator inserts
Post by: ChileRelleno on March 14, 2015, 04:33:53 AM
Quote from: Shark Hunter on March 14, 2015, 04:26:17 AM
We can load up on triple Whataburgers to Hold us Down! ;)
I haven't had a Triple Bacon Cheese Whataburger since my heart episode.  ;)
Title: Re: big boy senator inserts
Post by: doradoben on March 14, 2015, 06:21:33 AM
Daron, instead of tying a rope to the back of your harness, you may want to bolt one of these to the bumper hitch. It'll turn your truck into a sport fishing machine.. ;)


http://www.arrigonidesign.com/rod-holders/samson-post/
Title: Re: big boy senator inserts
Post by: Alto Mare on March 14, 2015, 11:44:17 AM
Quote from: doradoben on March 14, 2015, 06:21:33 AM
Daron, instead of tying a rope to the back of your harness, you may want to bolt one of these to the bumper hitch. It'll turn your truck into a sport fishing machine.. ;)


http://www.arrigonidesign.com/rod-holders/samson-post/

Definitely one of the best tool I've seen to date, thanks for sharing it with us.
I couldn't get the price, I'm wondering how much it costs, i'm sure it isn't cheap.

Oh yes, I see the price at the bottom, it is even more tan I expected, I was thinking $750 tops.

Oops! got distracted from the inserts  ::), those are sick looking Adam and I mean it in a good way.
Good point on the drag numbers, I'm noticing with these star reels, to get them extremely smooth at max, you need to almost double the numbers on drag.
Daron, good luck with the testing, the big boys are all yours ;). I'm wondering what you'll come up with, can't wait.
I bet the reel will feel silky smooth at 50Lbs.
Title: Re: big boy senator inserts
Post by: Three se7ens on March 14, 2015, 04:53:53 PM
Id like to get a count of who is interested in these.  It doesnt have to be a firm commitment to buy, just trying to get an idea of how many to make on the first run. 
Title: Re: big boy senator inserts
Post by: ChileRelleno on March 14, 2015, 07:09:25 PM
I'm in for one (1) 12/0.
Title: Re: big boy senator inserts
Post by: Shark Hunter on March 14, 2015, 07:29:34 PM
Quote from: doradoben on March 14, 2015, 06:21:33 AM
Daron, instead of tying a rope to the back of your harness, you may want to bolt one of these to the bumper hitch. It'll turn your truck into a sport fishing machine.. ;)


http://www.arrigonidesign.com/rod-holders/samson-post/
That Picture is not Me. I borrowed it from Rogue Hooker on SOS. He is a young Man from Austrailia. He asked me to Flash and tag him on instagram.  *bretto_rogueadventures*
I'm good for a pair of each Adam. I think Once Tom's sleeves are available, you will have a few more takers.
Title: Re: big boy senator inserts
Post by: Tightlines667 on March 14, 2015, 08:03:01 PM
I will take 1 of each to start, there will likely be more demand for the 12/0 sets.
Title: Re: big boy senator inserts
Post by: Strick on March 25, 2015, 05:41:31 PM
I'm in for one 12/0 and one 14/0
Title: Re: big boy senator inserts
Post by: Southernsharker on March 27, 2015, 05:09:15 PM
I'll take 1 14/0 and 2 10/0 just tell me when you need the money
Title: Re: big boy senator inserts
Post by: Three se7ens on March 27, 2015, 11:47:15 PM
Im putting together a full kit for the 12/0 and 14/0 for daron to test out on some sharks on his next trip coming up.  They will be available shortly thereafter, pending any changes or tweaks that have to be made. 

I expect the price to be in the low to mid $50 range for the complete kit of the insert and all washers. 
Title: Re: big boy senator inserts
Post by: crackerman on March 28, 2015, 12:39:42 AM
Ohhhh  yeah!!!!! I am so ready for this.
Now we really need an aluminum frame!!!
Title: Re: big boy senator inserts
Post by: Superhook on March 28, 2015, 01:43:45 AM
With a high capacity drag system , i wonder if the Jackasses will consider tobogganing or skiing behind sharks. Some of the ideas have been crazier.
Title: Re: big boy senator inserts
Post by: Shark Hunter on March 28, 2015, 02:27:56 AM
No Jack Asses here Ray. ;D
Title: Re: big boy senator inserts
Post by: Three se7ens on March 28, 2015, 04:10:11 AM
Quote from: Superhook on March 28, 2015, 01:43:45 AM
With a high capacity drag system , i wonder if the Jackasses will consider tobogganing or skiing behind sharks. Some of the ideas have been crazier.

https://www.youtube.com/watch?v=6zc79UQj1hQ
Title: Re: big boy senator inserts
Post by: Shark Hunter on March 28, 2015, 04:18:48 AM
I don't buy it. :D
Title: Re: big boy senator inserts
Post by: Maxed Out on March 28, 2015, 06:57:36 AM
   I not selling or buying........but that was darn tootin' funny ;D

  Probably a jet ski out in front pulling a fin, then at the end he is just riding the wave in, not getting pulled, then throws his rod and reel away ?? Yep, you're right daron, what looks like a rat and tastes like a rat, must be a rat...BTW, I never ate rat............or squirrel ;D


  Sorry we got this off track Adam. I have to agree with Sal, your work is amazing. I have a 16/0 that could use a facelift. I'd be interested in one for it when you get into production after testing..... if and when Daron returns from sharking/surfing  :D ....Daron, you should wear a lifejacket with sea rations attached, for when that great white tows you out to sea 8)
Title: Re: big boy senator inserts
Post by: Southernsharker on March 28, 2015, 11:00:51 PM
Using 50lbs of  drag on a 14/0 loaded with 200lb  braid and mono will be the sweetest setup for a 130 class reel here in florida. And so much cheaper then are tiagras
Title: Re: big boy senator inserts
Post by: Shark Hunter on March 29, 2015, 12:06:28 AM
I Hear ya. I'm all about cracking a joke, but I'm taking this Venture very seriously.
This is a first, and if you don't get on this train, you are missing out.
Title: Re: big boy senator inserts
Post by: RockyR on March 29, 2015, 03:08:32 AM
One for 14/0
Title: Re: big boy senator inserts
Post by: Three se7ens on April 04, 2015, 12:29:30 AM
Picked up some parts from the cutter, and have a full kit for the 14/0 together.  Still waiting on the 12/0 insert from the cutter, but I expect to have both kits in Daron's reels before his next fishing trip.  Cant wait to see the results, but Im confident the performance will be exceptional.   
Title: Re: big boy senator inserts
Post by: Shark Hunter on April 04, 2015, 12:32:03 AM
Good Work Adam! ;)
Title: Re: big boy senator inserts
Post by: RockyR on April 04, 2015, 03:22:31 PM
Nice!
Title: Re: big boy senator inserts
Post by: Alto Mare on April 04, 2015, 03:31:38 PM
Oh wow!!! I didn't see this latest. Adam, they look amazing I wonder how much I could pull with one of those. The big senators should feel silky smooth at 40#, you could probably smoke a cigar as reel in a monster ;D.
Very nice job!.
Title: Re: big boy senator inserts
Post by: Cortez_Conversions on April 04, 2015, 04:27:23 PM
Very cool!
Title: Re: big boy senator inserts
Post by: Shark Hunter on April 15, 2015, 10:50:48 PM
The Big Boys came today! I am impressed Adam. I will be slapping these in my ss sleeved 12 and 14/0 this weekend.
I am waiting for the new run of 113H gears from Black Pearl for my 113H insert.
113H, 114H/9/0, 12/0 and 14/0 inserts from Adam.
Title: Re: big boy senator inserts
Post by: Strick on April 15, 2015, 11:24:42 PM
I want some!! :o
Title: Re: big boy senator inserts
Post by: Three se7ens on April 16, 2015, 01:51:20 AM
Quote from: Alto Mare on April 04, 2015, 03:31:38 PM
Oh wow!!! I didn't see this latest. Adam, they look amazing I wonder how much I could pull with one of those. The big senators should feel silky smooth at 40#, you could probably smoke a cigar as reel in a monster ;D.
Very nice job!.

Isnt that how they did it in the old days with these reels anyways? :D

Looking forward to seeing the testing, and hopefully some sharks on the sand too.  Best of luck on your trip, Daron.
Title: Re: big boy senator inserts
Post by: Shark Hunter on April 20, 2015, 03:36:52 AM
Getting my 12/0 ready for battle with all the latest upgrades.
This is a prototype. I have some fitting to do.
I managed to fit eight of these drag washers in the insert. More then enough to rip this reel off the stand or pull me into the abyss.
I made a custom Delrin under gear and one on top the same size as the washers.
This was no easy task, but I managed to get it done. At the lowest drag setting, this reel is pulling at least 10 lbs. I will treat this one with the utmost respect. I realize its power.
Spooled with 1000 yards of 100 lb Bullbuster Mono. This is a 12/0 like no other.
Tom Hyrinuk prototype ss sleeve, Adam's prototype insert and Shark Handle. Lee's double ss dogs and a set of stainless posts. Bolted to a Calstar Baby Boomer Berserker Rod.



Title: Re: big boy senator inserts
Post by: Southernsharker on April 21, 2015, 12:11:51 PM
Daron keep me posted I can't wait for these to be available  I had 200lb test broke on a bridge Saturday  night using half a aj because I couldn't  put enough  drag on the 14/0 with this upgrade I know I'll turn them haha
Title: Re: big boy senator inserts
Post by: Rancanfish on April 21, 2015, 02:03:55 PM
Wow this high tech stuff is amazing.  How exactly did you get the remotes to control the drags.  ;D

Can't wait to hear how they work out. 

You sure keep pretty reels Daron.
Title: Re: big boy senator inserts
Post by: Shark Hunter on April 23, 2015, 05:23:03 AM
Thanks Randy. I'll keep you posted on these Brandon. I am actually a little scared of this reel. I know I can handle a stock 12/0 on full lockdown, but this one can handle some crazy drag numbers.
I will need to definitely control myself if I hook into something that needs the star cranked down.
I only have this coming weekend to get the 14/0 ready, I splurged for the ss posts mod on the 14 and 16/0. I will definitely keep a knife ready if I get in over my head.
Wish me luck guys. I feel good about this one. ;)
Title: Re: big boy senator inserts
Post by: bluefish69 on April 23, 2015, 04:33:04 PM
All you have to pack is Water Skies & you are ready to go.

Mike
Title: Re: big boy senator inserts
Post by: Shark Hunter on April 23, 2015, 08:00:49 PM
That's not the kind of luck I need Mike. ;)
Title: Re: big boy senator inserts
Post by: Sea Dweller on April 24, 2015, 12:32:12 AM
I am interested in one set for sure, possibly two. Depends on if I decide to keep my pristine 16/0 as a wall hanger.
Title: Re: big boy senator inserts
Post by: Shark Hunter on April 26, 2015, 06:43:21 AM
I got to work on the 14/0 this evening.
Adam, I replaced that original steel main with a new stainless one from Scott's and it is thicker on the bottom, leaving less space on the top.
I also opted for stainless posts for the 16 and 14/0.
Using 1/8" thick washers, I stuck with a 5 stack on this bad boy.
I got lucky being able to pull the original gear through the plate. Here is a great shot of Tom's prototype sleeve with simultaneous engaging stainless dogs from Lee.
After putting the stack together, just with 5 thick washers, There was not enough pressure on the stack.
I put a thin spacer on top and it was perfect. Probably 10 lbs with the star backed all the way off, just like the 12/0. I think I'm ready. I have a Delrin on the bottom and top.
Title: Re: big boy senator inserts
Post by: Tightlines667 on April 26, 2015, 07:58:33 AM
That thing looks pretty wicked Daron!

I think the gear sleeve, dogs, gear set, and posts will really strengthen the reel up.  Those inserts are going to make that drag smooth as silk.  

I think you ought to think of a fitting name for this 'hotrodded' big boy at somepoint.

The reel will handle alot, but I would definately precaution others thinking of using these against using one of the newer aluminum spools with these inserts.  

The only other upgrade(s) I think these big senators would truely benefit from is a beefer stand, maybe SS bars, and a bridge where the gear sleeve is supported at the plate.  These would greatly strengthen the 'frame', and sleeve againsy forces beyond what the origional engineers had in mind.

I envision either cast (like the old 130s), or annodized aluminum like those Cal offers for the old 80s.  Unfortunately the screw holes are misaligned slightly, and there is no room to drill/tap different ones.  I wonder how many would need to be made for a proper run?  The stock stands should be solid enough with the rod braces, and those SS arms should reduce reel twist under higher loads.  But over time they fatigue, and warp.  Guess its easy enough to replace the stock stand if/when it ever needs it.  

The reel should be able to handle big numbers as is, provided you don't try to crank under really heavy drag, at least not without handle assist, or as the locals here xall it 'Hawaii Style'.  The gears, sleeve, and dogs can certainly take it, but the stand post/bridge connection may fatique more quickly under heavier abuse.  

Most guys are not going to fish the new inserts at anywhere near what they are capable of, and even if they did, I think the reel is still capable to taking it.

Bearings might wear a bit under leavier prolonged loads too, but certainly will not be prone to catastrophic failure.  Hogh tllaranve aftermarket ceramics, might ail more quickly as well.  Be best to stick with stock (Abec 5 SS).

As Sal likes to say (or at least I think he does?) the strength in having this system, will likely be much smootherdrags when fishing the reel within its 'effective' range.   The drag curve should be a bit more consistent on this range as well (i.e. moving the star in one notch = 6lbs instead of 10lbs) when fishing nearer max. as well.

I am sure it will handle your sharks just fine.  It should pass any tests or paces you put it through on standup gear with flying colors.  

I think the only real issues that might arise, will be with decreased wear intervals over prolonged use.  What concerns me a bit, is the fact that many of the semicommercial guys here, spool their 14/0s up with 250lb mono, crank the drags down, and use the boat to turn, control, and quickly land big Ahi.  A more solid reel stand, and maybe alum. crossbars would definately stiffen the reel up, and provide some piece of mind if someone is plannimg to actually fish this reel at high numbers.

Old 80 internationals, as you know have alum side plates, more strongly supported drive shafts, much larger bearings.  They do have a propensity to twist the stands (often breaking the mounting tabs, when they get older/fatuged), and are fished at higher drag numbers with the duradrag upgrade.  A new stand fixes the problem.  Cal already took care of this.  *See attached pic.

Heat generation will be greater too, a SS star would help to avoid it getting locked to the sleeve when it swells after getting hot.  Try the test sometime with a torch.  As soon as it cools down it moves freely once again.  Guess this is why they were dumping buckets of water in the senator in Jaws.

These are great, simple, true workhorses of the big game world, but now they have been taken to a whole new level.  

Sorry for the diatribe, didn't mean to hijack the post.  

These inserts should be one of the best upgrades available for these larger Senators.
Title: Re: big boy senator inserts
Post by: crackerman on April 26, 2015, 11:58:48 AM
Why worry about the aluminum spool? I think it would be a bit stronger than the 3 piece one on the old
Title: Re: big boy senator inserts
Post by: Three se7ens on April 26, 2015, 04:21:51 PM
You probably already caught this, but be aware of the lip on the inside of the gear on some gears.  The hole in the first cf washer will need to be enlarged, and it might even take stacking 2 cf washers on the bottom to give enough height that the first metal washer wont bottom out on that lip.  I dont remember which, but one of those 2 gears you sent me had the lip, and one didnt. 

As always, it looks great, and Im sure it will perform just as well.

Title: Re: big boy senator inserts
Post by: Newell Nut on April 26, 2015, 04:38:07 PM
Daron

Be careful so we don't read about you getting drug out to sea. Next upgrade would be a fighting chair that hooks to your trailer hitch unless you are on a non drive beach. Have a safety plan of some sort.
Title: Re: big boy senator inserts
Post by: Shark Hunter on April 26, 2015, 08:01:25 PM
That's why I opted for the stainless gear Adam, It doesn't have that lip and I like the way the insert sat higher in the gear. I will be safe Dwight. I will keep some snips ready, If I have to cut the line if it locks up. I am also incorporating my Harness and belt into one unit with some clips. My belt unclips with one push.
Title: Re: big boy senator inserts
Post by: Tightlines667 on April 26, 2015, 09:57:28 PM
Daron,

Thats a great idea to have the ability to get out of your harness quickly.  Hopefully you won't have to hit the eject button, but better to be prepared.  A readily accessable knife would probably be your best friend. 

I've never seen a large senator aluminum spool fail.  I'm not sure what it would take to do so.  I imagine it would take alot to actually bring about a catestrophic type failure though.  I'm sure they would probably be fine under most comditions.  But the chromed-bronze spools are no doubt much stronger. 

Where are the myth busters when we need them?
Title: Re: big boy senator inserts
Post by: Shark Hunter on June 08, 2015, 03:18:57 AM
Since I didn't latch onto a Shark with Adam's insert. I finally did a static test with the 12/0. I used a 50 cal ammo can with 500 rounds of .308 inside. It weighed in right at 30 lb. All a stock 12/0 will put out. I lifted it clear of the deck without slipping. I eased it down and it felt pretty smooth. This is my nicest rig. A Calstar Baby boomer 130 spooled with 100 lb mono. I think the pic says it all.
The star was about a half a turn from full lock down. I think this is perfect. With the Delrin on the top and bottom, this is all the drag you will need. I know the math, says this could provide 100 lbs of drag. I think 50 is tops with the 8 stack of Versa drag. Perfection. ;) I don't want to push it any more than this.
A perfect balance of smoothness and power. Not enough to destroy the reel or me. ;D
Title: Re: big boy senator inserts
Post by: Three se7ens on June 27, 2015, 02:35:03 AM
I see you tried 8 cf washers, as well as 5 cf washers with the thicker stainless washers.  What did you think of one vs the other?  I could offer both combinations, or anything in between.  What did you end up with for the overall stack height?

Im getting ready to do a production run of these, but I dont plan on keeping them in stock like my other parts.  Ill start a new thread with pricing and you can put your name on the list there.  It will take me about 3 weeks from when I order the material to having kits ready to deliver, and payment wont be due until the parts are ready to ship. 

In the mean time, Id like to hear form Daron on the 5 stack vs 8 stack, as well as other peoples thoughts and requests.  The 5 stack will be cheaper, and more progressive at lower drags.  A 7 or 8 stack may be a bit smoother at high drag, but the minimum drag may be high, and it will ramp up quicker. 
Title: Re: big boy senator inserts
Post by: ChileRelleno on June 27, 2015, 03:36:56 AM
Hey Adam,
I finally got around to installing the 9/0 insert.
It didn't fit in the Pro Challenger stainless gear, took me an hour or so of careful fitting with a Dremel.
It fits great now, in/out like there's hair around it.
I do have another slight issue, the stainless washers are very tight on Alan's stainless gear sleeve, they go on but are so tight the drag doesn't back off like it should.
Which poses a question for anyone here, should I fit the washers or take a hair off the sleeve's flats?

Also, I'd like to have a backup drag stack for both the 9/0 and the 12/0 when they're ready.
Let me know how much and I'll PayPal you the funds, please and thank you.
Title: Re: big boy senator inserts
Post by: Three se7ens on June 27, 2015, 03:58:47 AM
Quote from: ChileRelleno on June 27, 2015, 03:36:56 AM
Hey Adam,
I finally got around to installing the 9/0 insert.
It didn't fit in the Pro Challenger stainless gear, took me an hour or so of careful fitting with a Dremel.
It fits great now, in/out like there's hair around it.
I do have another slight issue, the stainless washers are very tight on the gear sleeve, they go on but are so tight the drag doesn't back off like it should.
Which poses a question for anyone here, should I fit the washers or take a hair off the sleeve's flats?

Also, I'd like to have a backup drag stack for both the 9/0 and the 12/0 when they're ready.
Let me know how much and I'll PayPal you the funds, please and thank you.

File the washers, not the gear sleeve.  The sizing issues are why I have been putting off more insert kits, but the waterjet has been fixed now and is cutting fantastically.

The pro challenger gears do seem to be a much tighter fit on my inserts than the penn gears.  Sal had a hard time getting his to work too, but that exact one dropped right into a brass gear of mine before I shipped it.  Im reluctant to reduce the size much because that will leave a looser fit on the original penn gears. 

You bring up a good point though.  I do test fit all the parts I sell, but manufacturing tolerances can make parts that fit good for me not fit for someone else.  If anyone has an issue, please contact me.  I want to know, and Ill make sure you get taken care of.  I want me parts to fit as well as possible, and I cant do that without feedback. 
Title: Re: big boy senator inserts
Post by: Shark Hunter on June 27, 2015, 04:04:07 AM
Adam,
I haven't tested the 5 stack in the 14/0 yet. I will do it this weekend. With the thick washers, that's all you can fit in there. The eight stack in the 12/0 is gong to be hard to beat. I also put a Delrin on the bottom of the gear and a smaller one, the diameter of the washers, on top.
The height on the 12/0 insert with an eight stack is about perfect. I put a thin washer on top of the last CF, then the Delrin, then a thick washer.
The old 14/0 steel gear with the insert left a gap at the top of the gear I didn't like.(Far right)
I had one if the new stainless gears from Scott's. problem solved.




Title: Re: big boy senator inserts
Post by: David Hall on June 27, 2015, 04:17:45 AM
I'm in for a 12/0 set as well as the 9/0 your working on.
Title: Re: big boy senator inserts
Post by: ChileRelleno on June 27, 2015, 04:26:16 AM
Adam, your 9/0 insert fit perfectly in both stock Penn 9/0 steel & brass gears.
Was only too big in the Pro Challenger gear.

I don't mind a little fitting of custom parts, it is part of the fun of working on your own stuff.
Will do on fitting the washers, do that next time I open it up.
Title: Re: big boy senator inserts
Post by: Black Pearl on June 27, 2015, 01:48:56 PM
I just wanted to let you all know that the PRO Challenger main gear is the same on 6/0 and 9/0.
Title: Re: big boy senator inserts
Post by: Shark Hunter on June 28, 2015, 03:07:17 AM
I tested that 14/0 with the 5 stack. I was impressed. It was just like you said Adam. Ramped up quickly and not as smooth as the eight stack, but a lot smoother than stock.
My suggestion is just as you made mine. 5 Stack for the 14/0 and eight stack for the 12/0.
The 14/0 is all meat and potatoes. A Giant reel to get it done. The 12/0 needs all the help it can get compared to its bigger brother. I lifted the same 30 lb ammo can a lot easier than before. I think it has a lot to do with this nice Rainshadow Rod. It is a Cadillac! It is 5'8" E Glass. Lots of Backbone in this Rod. I backed the drag off and it fell smoothly. Quicker than an eight stack, but I think this combination is just what the doctor ordered. When you start stacking those thin washers in the 14/0 Gear, its going to be more like a 10 or 11 stack. I think is that too much and am afraid it will get jerky. We are good on the gears.


Title: Re: big boy senator inserts
Post by: Shark Hunter on July 02, 2015, 04:41:03 AM
I received my latest order from Scott's today. I ordered two more of the stainless gear sets for the 14/0 for Adam's Inserts. This is a big Chunk of Stainless Steel!
Title: Re: big boy senator inserts
Post by: oncebitten on July 11, 2015, 07:55:04 PM
I am always on the lookout for drag upgrades, can you explain to me, how this is achieved?

How does an aluminum sleeve insert (that will retain heat), increase drag to the amounts that are being stated? Shure you can stack thinner washers together with Carbon discs, to up your drag, but you could do that without the insert. Unless I am missing something, the insert will reduce the overall drag area of each disc, less surface area, less drag!
Title: Re: big boy senator inserts
Post by: Three se7ens on July 11, 2015, 09:20:40 PM
In a normal drag stack, only one side of each drag washer produces friction.  The drag washer is free to move between the two opposing metal washers.

The insert allows the carbon fiber washers to be keyed to the gear, and therefore both sides of each carbon fiber washer produce friction. This greatly increases the drag capacity for a given number of carbon fiber washers. Since its capable of making more drag, it takes less pressure to achieve the same drag, resulting in smoother and more consistent drag performance.

Also aluminum conducts heat very well, so it will draw heat out of the drag stack and dissipate it into the gear where it can be released.
Title: Re: big boy senator inserts
Post by: Tightlines667 on July 11, 2015, 09:45:02 PM
Quote from: Three se7ens on July 11, 2015, 09:20:40 PM
In a normal drag stack, only one side of each drag washer produces friction.  The drag washer is free to move between the two opposing metal washers.

The insert allows the carbon fiber washers to be keyed to the gear, and therefore both sides of each carbon fiber washer produce friction. This greatly increases the drag capacity for a given number of carbon fiber washers. Since its capable of making more drag, it takes less pressure to achieve the same drag, resulting in smoother and more consistent drag performance.

Also aluminum conducts heat very well, so it will draw heat out of the drag stack and dissipate it into the gear where it can be released.

X2

Well put sir!
Title: Re: big boy senator inserts
Post by: Shark Hunter on July 13, 2015, 05:40:02 AM
When Tom H. placed his order for two of each insert with eight stacks. I figured I better make sure they fit. I know the 12/0 does. The 14/0 does as well. I suggest you make both kits like this. The thin washers work fine, with one thick one on top. I thought the bigger insert would take more, but it is actually a tighter fit with the thin washers. After 7, I had to put the star on to smash them down to fit the eight.
The 5 stack with all thick washers is an option as well with the 14, but to keep it simple. Eight stacks will work. I hated taking this reel apart again, but it had to be done.

Title: Re: big boy senator inserts
Post by: oncebitten on July 13, 2015, 02:10:12 PM
Quote from: Three se7ens on July 11, 2015, 09:20:40 PM
In a normal drag stack, only one side of each drag washer produces friction.  The drag washer is free to move between the two opposing metal washers.

The insert allows the carbon fiber washers to be keyed to the gear, and therefore both sides of each carbon fiber washer produce friction. This greatly increases the drag capacity for a given number of carbon fiber washers. Since its capable of making more drag, it takes less pressure to achieve the same drag, resulting in smoother and more consistent drag performance.

Also aluminum conducts heat very well, so it will draw heat out of the drag stack and dissipate it into the gear where it can be released.

Thanks for the clarification.  I will look forward to when you are doing 9/0 inserts :-)
Title: Re: big boy senator inserts
Post by: Keta on July 13, 2015, 02:20:05 PM
Quote from: Shark Hunter on July 13, 2015, 05:40:02 AM
When Tom H. placed his order for two of each insert with eight stacks. I figured I better make sure they fit. I know the 12/0 does. The 14/0 does as well. I suggest you make both kits like this. The thin washers work fine, with one thick one on top. I thought the bigger insert would take more, but it is actually a tighter fit with the thin washers. After 7, I had to put the star on to smash them down to fit the eight.
The 5 stack with all thick washers is an option as well with the 14, but to keep it simple. Eight stacks will work. I hated taking this reel apart again, but it had to be done.



How thin are the thin washers?  I could run a small batch (10 or so) of .035" or .045" washers for R&D, but no production ones.
Title: Re: big boy senator inserts
Post by: ChileRelleno on July 13, 2015, 02:20:27 PM
He has already done one run of the 9/0 inserts.
I've one in my 9/0, need to put one in my 6/0 wide.
Encourage Adam to make more, get your buddies over here asking for them too.
Same goes for plates & frames, having 2-3 dozen people committed to them makes a run more likely.
Title: Re: big boy senator inserts
Post by: Three se7ens on July 13, 2015, 03:21:56 PM
Quote from: Keta on July 13, 2015, 02:20:05 PM

How thin are the thin washers?  I could run a small batch (10 or so) of .035" or .045" washers for R&D, but no production ones.

0.060 on these, and 0.031 on the 9/0 and smaller kits.


Inserts for the 6/0 and 9/0 are on order.
Title: Re: big boy senator inserts
Post by: Keta on July 13, 2015, 03:26:13 PM
Thanks. 
Title: Re: big boy senator inserts
Post by: oncebitten on July 15, 2015, 12:16:05 AM
Quote from: ChileRelleno on July 13, 2015, 02:20:27 PM
He has already done one run of the 9/0 inserts.
I've one in my 9/0, need to put one in my 6/0 wide.
Encourage Adam to make more, get your buddies over here asking for them too.
Same goes for plates & frames, having 2-3 dozen people committed to them makes a run more likely.

Are the 9/0 and 6/0 inserts the same?  I would love to see another run on those.  Plus Daiwa Sealine 900h, 600h, 450h & 50h, one day :-)

Seriously, I would be happy to put my money up front for a 9/0 set!
Title: Re: big boy senator inserts
Post by: mrand on July 20, 2015, 06:39:42 AM
I'm interested in one insert and 2 drag kits for the 14/0
thanks so much!

Also, possibly interested in the same for the 9/0

This is impressive!
-michael
Title: Re: big boy senator inserts
Post by: Shark Hunter on July 20, 2015, 07:46:53 AM
mrand,
The list is here.
This is a one time deal. I really appreciate Adam doing this. There will not be anything like this again.
http://alantani.com/index.php?topic=14751.0
and Welcome!