Recently got given a 114HL to do what I pleased with. Usual story, had been sitting in corner of someone's shed, had parts pilfered from it, broken drag star, rings all cracked, basically looking pretty sad. But after reading plenty of threads on here Tanking these old Senators, I thought "I can do that", but with a twist. I figured as a first step to restoring this reel, I'd challenge myself to make new rings....from stainless.
First up was to get some 316, 6mm plate with which to cut them from. Not having access to a plasma cutter, meant it was going to take a fair bit prep work to get discs fabbed to work from. Before going to work, I cut myself 5, 125 x 125 squares from the 400 x 400 piece I bought.
Once at work, first thing I made was the drilling template for the ring's holes. Found a piece of scrap 8mm plate for this.
Measured the spigot diameter where the rings mount on the side plates, was surprised to find quite a difference between the left and right sides.
Left 103.85mm
Right 104.15mm
So I decided to turn the template down to the left side diameter. Cut a square about 120mm from the 8mm plate, found the centre, marked the final diameter roughly, and trimmed the square to a octagonal shape. Drilled the centre with a 8mm drill. Mounted the plate on a crude mandrel arrangement and turned it down to size, being careful until the plate was true'd to a circle.
(http://i1083.photobucket.com/albums/j393/westozwayward/Mobile%20Uploads/photo_zpsbcffebc4.jpg) (http://s1083.photobucket.com/user/westozwayward/media/Mobile%20Uploads/photo_zpsbcffebc4.jpg.html)
Next up, made an insert to fit in the bearing bore to take a M8 bolt to help centre the right side plate over the template.
(http://alantani.com/gallery/21/10783_28_08_17_2_56_59_2129230.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_3_15_00_213352293.jpeg)
Located an old pin punch and skimmed the shaft down to a snug fit for the screw holes in order to transfer punch the centres of the holes to the template for drilling. Tubolcain on YouTube has a couple of good videos on this.
(http://alantani.com/gallery/21/10783_28_08_17_2_55_07_212861698.jpeg)
With the hole centres transferred, the 8 holes were drilled with a 4.5mm drill (didn't have the correct size imperial drill at work, so this was close enough).
(http://alantani.com/gallery/21/10783_28_08_17_3_22_15_21352184.jpeg)
A quick check with a few screws to make sure all was OK. The holes lined up very well.
(http://alantani.com/gallery/21/10783_28_08_17_3_04_25_213052485.jpeg)
Now for the stainless. Mark the centres of the pre-cut squares and scribe oversize circles for the ringside. Drill the centre's M8. I kept a pretty slow chuck speed, 250 rpm, and plenty of cutting oil. Didn't burn out the HSS bit.
(http://alantani.com/gallery/21/10783_28_08_17_2_57_52_212941946.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_3_21_30_21349944.jpeg)
Trimmed the squares to rough octagons with angle grinder and 1mm cut off wheel.
(http://alantani.com/gallery/21/10783_22_09_17_3_27_39_21974176.jpeg)
Mount plate onto mandrel and true up. Note all stainless turning was done at 140rpm, HSS bits, with copious emulsified cutting coolant. It was a slow tedious process.
(http://alantani.com/gallery/21/10783_28_08_17_3_21_20_21348248.jpeg)
Once I had 4 pieces tru'd up, next thing is to cut the ring blanks from the plate. Had to shape up a tool for this process that would not rub as it parted off. Despite trying to manage the heat build up, it still required sharpening a few times as this procedure was tough on the tool.
(http://alantani.com/gallery/21/10783_28_08_17_3_11_29_21326294.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_3_01_41_21301753.jpeg)
Finally got the blanks separated ready for turning to size to fit the side plates. This prep work was the most difficult part of making these parts.
(http://alantani.com/gallery/21/10783_25_09_17_2_51_33_219772143.jpeg)
Now to the business end. Mount the roughed out rings into the chuck. Used an external jaw as a parrallel to get it close enough to being true.
(http://alantani.com/gallery/21/10783_28_08_17_3_00_20_21297357.jpeg)
First cut the internal bore of the ring, a shade over 86mm diameter.
(http://alantani.com/gallery/21/10783_28_08_17_3_07_07_21311475.jpeg)
Then scoop out to accommodate the side plate
(http://alantani.com/gallery/21/10783_28_08_17_3_13_55_21332390.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_3_11_13_213242209.jpeg)
It doesn't matter if you bore too deep, it can be trimmed back later.
(http://alantani.com/gallery/21/10783_28_08_17_2_58_33_21296312.jpeg)
Just make sure to leave enough thickness of the face flange to true up when the ring is remounted on the chuck. Mark the position of one jaw where is clamps to the ring, minimizes your errors a little.
(http://alantani.com/gallery/21/10783_28_08_17_3_10_27_21321886.jpeg)
Remount ring on chuck, tightening jaws outward.
(http://alantani.com/gallery/21/10783_28_08_17_3_29_07_21371955.jpeg)
Face off the flange to correct thickness, 1.1mm.
(http://alantani.com/gallery/21/10783_28_08_17_3_17_07_213432494.jpeg)
Then turn down the outside diameter, maintaining a stainless thickness of about 1mm.
(http://alantani.com/gallery/21/10783_28_08_17_3_27_54_213692121.jpeg)
Once I was happy with the ring fits on the side plate spigots, time to drill the screw holes.
Fit ring onto template made earlier. The left plate rings should be a very snug fit
(http://alantani.com/gallery/21/10783_25_09_17_12_45_36_219961714.jpeg)
Drill one hole with 4.5mm bit, plenty of cutting fluid. Chuck 400rpm.
(http://i1083.photobucket.com/albums/j393/westozwayward/Mobile%20Uploads/photo_zps35233844.jpg) (http://s1083.photobucket.com/user/westozwayward/media/Mobile%20Uploads/photo_zps35233844.jpg.html)
Place a M4 screw through and tighten down. This will prevent the ring moving on the template. Drill next hole, and add another screw. This was sufficient for the left side rings, but I used 3 screws for the right side rings.
(http://alantani.com/gallery/21/10783_28_08_17_3_27_37_21368327.jpeg)
All drilled. Repeat for other rings. I used a couple of small pieces of 0.15mm shim steel to snug up the right side ring's fit on the template.
(http://alantani.com/gallery/21/10783_28_08_17_3_25_09_21360153.jpeg)
Removed any little burrs with deburrer or a grind stone in the Dremel.
Also used a buffing disc to smooth off the outside surfaces.
(http://alantani.com/gallery/21/10783_28_08_17_3_26_04_21363413.jpeg)
For the gear box profile, bolted on the original ring over the new stainless one and marked the indent with a permanent marker. The area to be removed was carefully roughed with a file, then the Dremel was used with a grinding stone.
(http://alantani.com/gallery/21/10783_28_08_17_3_11_23_213252451.jpeg)
Final check for fit, and assembly.
(http://alantani.com/gallery/21/10783_28_08_17_3_16_17_213391625.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_3_20_55_213471854.jpeg)
Will polish the rings to high shine at a later stage.
So far have put about 30 odd hours into making these rings. Probably an hour or two more to polish to a high gloss.
Another note, I had to wear leather gloves while handling parts and the lathe. There are a lot of fine needle like shavings that are created making these, was picking splinters out of my hands constantly, even with gloves on.
Hoping to get a T60NK kit for this reel. I have already got the stainless sleeve, will possibly go the BP Gears down the track. Will be making some more stainless parts, the old ratchet system will be remade, and the spacer under the star are the next on the list. I intend to not bother with the harness lugs, but will make some filler pieces to take up the space under the rings. Will also take to the side plate for the extra dog(s). Have already made those.
Will post again when I have made some more progress.
Absolutely amazing :) . Now all it's needed is a Tiburon frame and a full stainless steel geartrain and sleeve.
Wow!
That is impressive stuff!
Nice work!
I'm in awe! Amazing!
Karl
WOW :o :o :o
Beautiful work, can't wait to see what else you have. Thanks for sharing.
Sal
Very nice. And thanks for putting together the presentation. Very interesting to see a metal artist at work!
Impressive! ;)
(http://i1083.photobucket.com/albums/j393/westozwayward/Mobile%20Uploads/photo_zps23edf4f6.jpg)
That is a piece of art.
Can you imagine if that was programmed in a cnc machine...
photo of the month! let's send this man a wrench!!!!!!
If this is the first step, I'm very excited for the next one!
;D :o ;D
Karl
Nice!
Beautiful workmanship there. It is amazing the work some of you guys can turn out witht these lathes...All I can say is WOW!!!
Can you imagin have these type of rings on your 16/0, 14/0, 12/0, 10/0, 9/0, 4/0, 3/0, 2/0, and 1/0 senators? I'm starting to drool and I don't even own many of those reels.
Lovely workmanship there Rothmar2, you make it look easy.
It took a lot of good machining to produce 316 rings of that quality.
They will never crack like the stamped brass ones.
Stand by for orders from the 16/0 collectors ;)
I really don't know what to say, other than Thank You for the Generous Words. I certainly would never consider myself an artist with metal, I think a "lucky, persistent hack" is a more appropriate term. Lucky in that I seemed to have got it (fairly) right the first time. And "hack" as I'm certainly not a qualified fitter and turner. There are thousands of people out there, unsung hero's in my book, that are worthy of the title "metal artists".
There is still the issue of countersinking the hole on the outside right ring which the free spool lever passes over. I have to very carefully continue to widen that out a little as the lever catches the screw head.
And Alan, I've already got a wrench from a previous post, that one will last me until I'm six feet under! ;D
But the new wrenches are etched with alantani.com in them...
Very well done,
The important question is; now that you have all the jigs made up how many hours would it take to make another set(s)
Ron
Quote from: Irish Jigger on March 31, 2014, 08:52:18 PM
Lovely workmanship there Rothmar2, you make it look easy.
It took a lot of good machining to produce 316 rings of that quality.
They will never crack like the stamped brass ones.
Stand by for orders from the 16/0 collectors ;)
I'm not going to ask Tom. Especially something that takes 30 hours to make. ::)
If Rothmar doesn't want that wrench, I'll take it! I have at least 6 photos of the month and no wrench. :'(
I had to buy mine. ???
And I don't even have a single photo of the month yet ... Er go..had to buy mine too.
Maybe you are just being Held to a higher Standard John! ;)
I'm just kidding about the wrench. The one I have is fine. ;D
Geez, that was ambitious. You really, really, really wanted those rings. :)
That is a pretty stout machine you have. Have you considered lathe spinning those instead, not leastly now that you have a good mandrel? It still entails all the work of making the rings, but at least you don't have to work from thick plate.
.
Rothmar that work you did is stunning. Wow... 30 hrs..those rings won't come cheap for those who desire them.
myself included :D
you get another wow for that project mate!
I just took in a beauty of a 12/0 ... a shame ...all the rings are tossers ;)
Erik, I certainly didn't make these and post this to make money. It was more of "I think I can solve my problem by doing this myself" type of thing. Senator parts aren't as readily available in Australia as they are for you guys in the US. Sure, I could have just bought some from Scott's, or off EBay, but I just thought can they be made "better". Yes they can. My aim was to inspire people to maybe have a go themselves. I'm sure there are others here that have the ability to make these. I'm sure this is not the only way to go about this. As Robert has suggested "lathe spinning". I don't even know what he means by that (hence my "hack" status). I have already had an offer to have rings roughed out on the water cutter, that would save a heap of time. Plus the off cut could be used to make rings for the larger or smaller senators.
I think, even with an accurately precut ring, I could probably get a ring turned out in 3-4 hours each. That would include the polishing, which I haven't even attempted yet.
There is a lot off possibilities here. But one thing for sure, the stainless rings will be stronger and last longer than the originals. Isn't that why so many on here have experimented with these Senators in the first place? Taking a legend, and making it even more so of one. I also want this reel to outlast me.
I was actually joking about you making these comercially. Gotta tell you though, if you could get the price down I would become your costumer. Really nice work.
Ron
Cheers Ron. As far as I'm concerned it is not viable to do this on any commercial level from Australia. There just isn't the following for these reels here as there maybe once was. But I can see there could be an albeit small market over there. I say to anyone over there "go for it".
The real inspiration for me came from guys like Sal, Keta, and others that have breathed new life and purpose into these reels. In today's "throw away mentality" of society, what these guys have achieved, and continue to achieve, is all the inspiration this hack needed.
Respect to all of you who care about these reels.
Quote from: Rothmar2 on March 31, 2014, 10:05:43 PM
I really don't know what to say, other than Thank You for the Generous Words. I certainly would never consider myself an artist with metal, I think a "lucky, persistent hack" is a more appropriate term.
You are a modest guy, Rothmar. I think we are all impressed with your imagination and talent. You are definately thinking outside of the box.
George
Quote from: Rothmar2 on April 01, 2014, 03:02:31 AM
Respect to all of you who care about these reels.
When you Start Modding a Senator Rothmar. It gets our attention. ;) Modest Indeed! ;D
Quote from: George4741 on April 01, 2014, 03:59:01 AM
Quote from: Rothmar2 on March 31, 2014, 10:05:43 PM
I really don't know what to say, other than Thank You for the Generous Words. I certainly would never consider myself an artist with metal, I think a "lucky, persistent hack" is a more appropriate term.
You are a modest guy, Rothmar. I think we are all impressed with your imagination and talent. You are definately thinking outside of the box.
George
Quote from: Shark Hunter on April 01, 2014, 04:09:07 AM
Quote from: Rothmar2 on April 01, 2014, 03:02:31 AM
Respect to all of you who care about these reels.
When you Start Modding a Senator Rothmar. It gets our attention. ;) Modest Indeed! ;D
x2
x2 Rothmar, I didn't want to imply you were in it for the money buddy... I'm stoked you had the guts to try my man!
I got a kick outta your own description: "" I think a "lucky, persistent hack" ""
.. now I have a new description for myself too ;D ;D
Keep up the good work!
Cheers
Thanks for sharing. very good pictures and text info.......you are an inspiration to us all. keep it up......and good fishin too!!!!!
Quote from: Rothmar2 on April 01, 2014, 02:21:03 AM
As Robert has suggested "lathe spinning". I don't even know what he means by that (hence my "hack" status). I have already had an offer to have rings roughed out on the water cutter, that would save a heap of time.
Spinning is a type of cold forming in the lathe. You would put a sheet metal disc in the lathe together with a mandrel of appropriate size (your steel template) and use a roller tool to form the outer edge over 90 degrees. Working time in lathe, 60 seconds, plus trimming. Plus making the blanks of course.
Advanced scholars can use the technique to make complicated vases, chalices and so on, but it is still a great trick for a hack to have in their repetoire for geometrically simpler items.
http://en.wikipedia.org/wiki/Metal_spinning
.
A lantern is the first spinning project most get in school, I have thought that rings could be made that way, but those milled rings here sure are pretty.
Ron
Wow! Just read the wiki link, and then did a YouTube search. This is the way to do it!
Seeing as the rings are pretty much 1mm thick, it is well within the scope of this technique. Much less time and wastage involved. Looks like I've got some more research to do. My only reservation would be rigidity of the spun part, not that it would matter greatly. Definitely something I would like to try at some stage.
it has probably been suggested, but how about producing some for the 4/0. just an idea... :) i'll be the 1st one or 2nd or 3rd to buy... ;D ;D ;D
Started on the double dogging today. Set up the dremel tool on my bench drill to mill the space for extra dog.
(http://alantani.com/gallery/21/10783_28_08_17_3_14_09_21333245.jpeg)
I went for alternating at this stage, but will make another dog for simultaneous engagement.
(http://alantani.com/gallery/21/10783_28_08_17_2_59_43_212971116.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_3_30_54_213781703.jpeg)
While I was trying to figure out how to get the right side-plate all together, this turned up......
(http://alantani.com/gallery/21/10783_28_08_17_3_09_46_213192133.jpeg)
Couldn't help myself, I had to have a sneak peek!!!!
(http://alantani.com/gallery/21/10783_28_08_17_2_54_32_21284160.jpeg)
Still a long way to go. Have to get in some more screws, the reel was missing a heap when I got it. Also the drag star is broken. Any word weather a stainless star is available yet for the 6/0? Will also look into new handle and crank soon, will have to start saving for BP gears as well.
Thank you so much Alan for supplying the frame.
Am going all the way with this!
That is a very sexy reel. Congratulations!
Ron
NICE!!
Those rings really set that reel off! Rothmar! You are on your way buddy! I suggest one of Lee's Keta Krank's and a Kokelar grip from Alan. Without the slots for the harness lugs, it gives it that sleek look. :o I am Impressed! ;)
That's a nice look. Impressive. I want one..or two
WoW :o :o That's a work of art man.. gorgeous!
Rothmar, those stainless rings are the missing link in the whole evolution of the Senator to the TaNK !
Nice work..
I read up on the spinning too... Boom!
S.H. Yes, I'll definitely be going Keta's crank, but I love those anodized ally handles.
Erik, the spinning is definitely the method, for someone skilled at it. I'm not too sure I'd be able to get them accurate enough without some considerable practice. I would also need to make another mandrel due to the subtle differences in spigot size between each side plate. But I think this would be the way forward, for someone willing to put the time into producing them for others.
Quote from: erikpowell on April 12, 2014, 07:26:38 AM
...those stainless rings are the missing link in the whole evolution of the Senator to the TaNK !
X2
i'm really impressed. how i wish i have the tools to put my ideas into realities. oh well...:)
WOW...this makes me want to go buy a lathe and mill...Stellar work :o
Have got a little more done recently. My last trip to work was busy, but found time to advance things a bit further.
First up was to remake the ratchet.
(http://alantani.com/gallery/21/10783_28_08_17_3_29_21_213722264.jpeg)
I had to demel away the pressed rivet to get it apart
(http://alantani.com/gallery/21/10783_28_08_17_2_55_47_212881531.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_3_13_33_213311267.jpeg)
I had pre-ordered some E clips from Scotts to make the newer updated removable ratchet set-up, a much better design. Just used a few drills to find the shaft size that the E clip would require to get a good hold.
(http://alantani.com/gallery/21/10783_25_09_17_7_01_24_219972082.jpeg)
Also take a few measurements from the original piece for reference
(http://alantani.com/gallery/21/10783_28_08_17_3_03_16_21304507.png)
Scrounged a 16mm 316 stainless bolt to turn this piece down from, and mount in lathe
(http://alantani.com/gallery/22/10783_25_09_17_7_23_41_22000450.jpeg)
Measure off knob height, and part off, and roughed sized the rest of the shaft to be finished later
(http://alantani.com/gallery/22/10783_25_09_17_7_26_50_220012466.jpeg)
The head was shaped with a few cuts to rough down, and then shaped by hand using a few different rat-tailed files, some emery of various grades, before final polish with Autosol. I tried to remain faithful to the original shape.
(http://alantani.com/gallery/21/10783_28_08_17_3_28_39_213701577.jpeg)
Turn down the rest of the shaft to the diametre for a snug fit through the sideplate
(http://alantani.com/gallery/21/10783_28_08_17_3_10_04_213202457.jpeg)
In this next shot, I have turned the end of the shaft down to 3.5mm as the boss diametre for the ratchet, and then shaped a thin HSS tool to cut the groove for the E-clip.
(http://alantani.com/gallery/21/10783_28_08_17_3_20_15_213462479.jpeg)
Once happy, part the piece off, leaving a flange of 0.5mm thick for the E-clip to be held in. The boss length is a shade over 3mm as I will be using 3mm stainless to shaped the ratchet from
(http://alantani.com/gallery/21/10783_28_08_17_3_15_54_213371208.jpeg)
Remove the remaining piece left over from parting off with a belt sander, and then done. You will notice that there is a slight difference in the knob sizing, this was done as I have made some thin delrin washers to place either side if the side plate so as not to wear away at the plate by the ratchet in and out.
(http://alantani.com/gallery/21/10783_28_08_17_3_04_39_21306388.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_3_21_46_21350982.jpeg)
Next drill a 3.5mm hole through a piece of 3mm thick flatbar
(http://alantani.com/gallery/21/10783_28_08_17_2_56_41_212911638.jpeg)
Use a bolt to hold the original ratchet in place to mark around
(http://alantani.com/gallery/21/10783_28_08_17_3_16_27_213402328.png)
(http://alantani.com/gallery/21/10783_28_08_17_3_23_07_21355825.jpeg)
Carefully cut out and file to shape. Now the first ratchet I made was no problem fitted, it slid in and out on the copper spring, but with the left side bearing screwed in to take out all the axial spool play, I noticed that the wear pattern on the ratchet wheel of the new Tiburon spool, was only showing a very slight overlapp of the rachet and the wheel, only about 0.5mm, and subsequently the ratchet wasn't very loud, and actually skipped off every now and then and put a bit of binding on the spool as the rachet would now rub on the side of the wheel, rather than engage with the wheel teeth (if that makes sense). I currently have a 0.5mm shim made to rest up against the right side shaft bearing to make the spool rest more to the left. This concerned me, as here is a shot of the original spool, and you can see what has happened to the ratchet wheel and the way it has been worn down. The photos I took of the wear on the new Tib spool wheel, don't show this problem very well.
(http://alantani.com/gallery/21/10783_28_08_17_3_11_05_213231437.jpeg)
So I re-made the rachet from 5mm stainless flatbar, with a step to give more interference with the wheel, ie like this.....
(http://alantani.com/gallery/21/10783_28_08_17_3_16_47_213421362.jpeg)
The ratchet is now much louder, and does not slip off. There is a delrin washer either side of this assembly to protect the sideplate.
I also made a handle from stainless. I didn't get any fabrication shots, as I forgot to bring my phone with me. But here is where I'm at. The bush around the shaft is delrin. The actual handle has been drilled from each end to save weight. The shaft is a 6mm cap head bolt, with the outer sleeve 12.5mm diametre over the bush, and it screws into the handle with a 3/8 BSP thread. Its not finished, there is a little more honing to be done, as it is a little tight at this point. I was going to make a crank as well, but run out of time. Keta, if you're reading this, I'm still keen to purchase one of your cranks to save myself this work, I feel your's will be of much better quality than what I will be able to make myself.
(http://alantani.com/gallery/21/10783_28_08_17_2_53_18_21280986.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_3_26_14_213641663.jpeg)
I am hoping to order a set of BP gears and the yoke this leave, and then I will be very close to being ready to fish this reel.
That Handle is Sick! :o Awesome job My Man!
I just made this topic a sticky and I believe it deserves it. There is a lot going on here and don't want it to get lost in the shuffle.
I'm always impressed with your work Chris, thanks for bringing it to us.
I noticed that your 114H plate ( the one with the stainless rings) has a chip on it, that reel is too nice for that. I will be happy to take one of my reels down and send you a nice set, all I need is you address, your reel deserves it more than mine.
Sal
The workmanship displayed in this thread is outstanding.
The handle however is just a work of art.
(http://i1083.photobucket.com/albums/j393/westozwayward/Mobile%20Uploads/photo_zpsfcf428d8.jpg)
Sal, I agree this should be a sticky. It always amazes me with what can be done with a lathe. I give this 5 WOWS. Dominick
Your not kidding John and Dominick! I think that's the first custom stainless handle I've ever seen and I like it! ;)
I like it a lot!!! :P
I already have the wheels turning. Custom ss 12/0 bridge, sleeve, double dogs and handle. Bam! ;D
I give it 10 WOWS! and the Double Snap! :D
Once again I'm lost for words for the acknowledgement Guys. I really hope this inspires others to have a go at putting these extra's into their reels. It doesn't have to just be Senator's either. Will put up the TLD double dogging soon, with a bit of spice there too!
Sal, thank you for the above and beyond generous offer, but it should be me sending you a set of rings on behalf of the rest forum, for the freely given advice and guidance you pass on to us all. It's all good. Remember, this is not a display reel, I fully intend to fish this reel....hard. For the time being, the scratches on the side plates do not worry me in the least, and I know during the course of me fishing this reel, it will probably get a few more. I would hate to wear out another perfectly good set of plates at this time. Your offer shows what is so great about this forum. I would love to see some others have a crack at what I've attempted here, and post for us all to see. I certainly would never have attempted the work I have showed, without being inspired from many on here.
Chris,
Many thanks for sharing your work with us. My man Sal is an angel in disguise here. He has made many a fishermen happy here! Including myself. You are too Humble! ;)
QuoteI give this 5 WOWS.
Spot on Dominick - I wholeheartedly agree.
Quote...Sal is an angel in disguise. He has made many a fishermen happy here!
And likewise Daron, well said ;)
QuoteYour offer shows what is so great about this forum.
Alan's place is the best - such an inspirational collection of characters.
Cheers to you all!
All the best, Justin
WOW!
You work offshore?
Quote from: CaptDavDavis01 on August 18, 2014, 01:43:50 AM
WOW!
You work offshore?
Yes, mostly way offshore Broome, Western Australia
Rothmar,
You are one talented guy.
That handle is a thing of beauty, but you've impressed me big time with those rings. WOW!
Keep at it, and I can't wait to see what's next.
Thanks for showing us the possibilities.
Dom
Cheers Dom, have a couple more little twists to this build to come, just got to find the time to do it.
Other reels to service, and a bunch of big Flashy Profile Flies to tie for someone who has a trip planned to Tonga, and chase some sea-runner trout while home. Then there's the wife and kids too......
Just got home from work yesterday to find my gears have arrived.Thank you to Alan C, and Mystic Reel Parts. I would have bought from you direct Alan, only I had a bunch of other parts for other reels to order and needed to combine them all into one package.
(http://alantani.com/gallery/21/10783_28_08_17_3_05_28_21308592.jpeg)
So I'm now almost ready to fish this reel. When I get some time over the next few days, I will show the composite Delrin/Stainless top hat I made for the drag stack, with dimensions, and why I will probably have to refine it a little, as I'm not 100% happy with it. I had also been in contact with Adam for one of his custom handle arms, but for reasons I will explain, I decided not to go with one of his well made cranks, and took it on myself. Its nothing against your products Adam, it was a case of necessity for the stainless handle I had turned. Basically it came down to correcting something I hadn't considered. In fact I have made a few little ball-ups on this build, which I'll elaborate on when I post again.
"Edited as per Moderators to correct Scott's Bait & Tackle over to their new store name Mystic Reel Parts / www.mysticparts.com"
Stunning engineering - An Uber Tank :)
can't wait
what a cliff hanger!!
Quote from: jonnou on October 15, 2014, 08:07:47 AM
can't wait
what a cliff hanger!!
x2 ;D
Never mind fishing it, that reel belongs in the museum. I can't wait to see the finished product.
Well, a frustrating day trying to install the new gears. There is a bit of a grinding hum to the gears, and I can't get the reel into free-spool, the jack is getting jammed.
The yoke is the cause I'm sure. Going to have to go over everything with a fine toothed comb. I'm sure there is a reason behind this, I just haven't been able to pinpoint it yet. Just need to walk away from it for a bit.
Everything was fine with the original gear, pinion and yoke.
Rothmar2
Don't get mad get even. Sal did the grinding on my 6/0 for the second Dog & I bought all new SS insides. I have started & put it away 4 times so far since Spring.
Mike
Quote from: bluefish69 on October 16, 2014, 03:44:53 AM
Rothmar2
Don't get mad get even. Sal did the grinding on my 6/0 for the second Dog & I bought all new SS insides. I have started & put it away 4 times so far since Spring.
Mike
Not mad yet, I had the funny feeling this might happen. I seemed to recall reading about similar problems with installing these gears on here. I think the jamming can be cured by carefully bevelling the edge of the yoke where the jack tabs pass over. The grinding I'm guessing could have something to do with the shim I have resting against the right side bearing to take up the sideways play on the spool. It's quite thick, I may have to remake it thinner.
The only thing that did my head in, was I was greasing all parts as I was assembling, in order to get this side ready to be fished. Gonna have to clean it all off in order to check carefully where my problem lies.
Certainly not giving up at this point. I have a bunch of pics I will get up ASAP.
Make sure you smooth out the jack tabs too. That makes a big difference. Usually on all my stainless yoked reels, that is all that's needed. if you don't. They will catch every time.
Doh! Doh! Doh!
(http://alantani.com/gallery/21/10783_28_08_17_2_54_55_21285496.jpeg)
Amazing how easy it is to be blinded by ones own ignorance.
I walked away for a couple of hours, had a cup of coffee, sat back down and spotted it straight away!
How embarrassing! Anyway, free-spooling is now slick, but there is still a bit of a whirr about the gears, but no roughness transmitted up the crank as before. The dogs are now super quiet now they are greased up.
Will get some more details up when I get some more time. For now, I am happy I got through this stuff up!
I wouldn't worry too much about the gear noise. Just make sure they are greased well. I have some older 12 and 14/0's with steel gears that sound like a motorcycle! ;D I still trust them. ;)
A Funny story, after getting back from my last Shark Trip. I was respooling a 14/0 from one reel to another. My Boy happen to stop by and I gladly let him reel. He rested the reel seat on the floor, my Wife was downstairs and thought the neighbor was revving his truck up from the gear noise. :D
cool you got it sorted
You are a real man to show your mistake
others wouldn't
I have done these sort of things multiple times
some of the easy things are the big trips
more power to you and thanks for sharing
Cheers Jon
That's pretty funny SH, and a touch cute. Not afraid to show my mistakes John, won't be the last one I make ::)
Here is how I made the top hat....
First started off with scrap 30mm stainless shaft
(http://alantani.com/gallery/21/10783_28_08_17_3_27_20_213661819.jpeg)
Rough down to about 22mm diameter
Drill the sleeve bore to 14.5mm. Ideally 14.3mm would be better, this would leave a clearance on the gear sleeve of slightly less than 0.1mm. I only went this way due to the drills I had at hand.
(http://alantani.com/gallery/21/10783_28_08_17_3_30_18_213762138.jpeg)
Then skim a length of 10mm to 18mm diameter
Take the shaft out at this stage and put the Delrin stock into the chuck. In this case I have 40mm.
Turn down a spigot to 29mm dia, and then drill an 18mm bore.
Quick check to make sure the stainless sleeve is a semi tight fit
(http://alantani.com/gallery/21/10783_28_08_17_3_29_34_213731180.jpeg)
Then turn a shoulder to 20.8mm over a length of 5mm
(http://alantani.com/gallery/21/10783_28_08_17_3_21_56_21351388.jpeg)
Put a little tapered shoulder on this. This leaves the 29mm flange 4mm thick.
(http://alantani.com/gallery/21/10783_28_08_17_3_15_17_2133653.jpeg)
Cleaned up the little burr with emery.
Part the delrin top hat off. Total length of this piece is 10mm.
Put the stainless back in the chuck, and trim the top flange to 20.8mm, then part off the stainless sleeve with the top flange being 1.5mm thick.
(http://alantani.com/gallery/21/10783_28_08_17_3_08_31_21315765.jpeg)
Press the two parts together. Total height 11.5mm
(http://alantani.com/gallery/21/10783_28_08_17_3_23_38_21357939.jpeg)
Will get some details of the handle/crank up shortly.
Well done! Making dreams a reality, one part at a time :)
You do some beautiful work Chris, I'm glad you're here with us.
Sal
Hi Chris --
What a clever and simple idea -- just takes thought and skill.
Never quit trying to make the good better.
And the great greater.
Beautiful work!
Best,
Fred
Just out of curiosity, why didn't you make the top hat out of stainless steel and the sleeve out of Delrin? To me, you would want something extremely solid pressing down on the drag washers, and the delrin would be a bearing cushioning the top hat from the gear sleeve. what is your take?
Delrin is very strong, I've been testing a sleeve made from Delrin on my reels for some time now and it is still holding up. I've been squeezing it to 30+lbs.
Here is a shot of the Delrin sleeve holding 320+lbs for a couple of days.
Yes, I'm not all there ;D
(http://i766.photobucket.com/albums/xx305/pescatore3/013_zps0fe1aca4.jpg) (http://s766.photobucket.com/user/pescatore3/media/013_zps0fe1aca4.jpg.html)
(http://i766.photobucket.com/albums/xx305/pescatore3/007_zps583a6d35.jpg) (http://s766.photobucket.com/user/pescatore3/media/007_zps583a6d35.jpg.html)
I like what Chris is doing, very good idea. That reel should feel as smooth as silk. But he needs to place one under the gear as well.
I have made the UG washers as well, I made a few of varying thicknesses.
(http://alantani.com/gallery/22/10783_11_10_17_1_40_47_220701626.jpeg)
In this case I am using one that is 0.8mm thick. I found a 1mm thick one led to the top hat rubbing ever so slightly in the gear recess on the right side plate. Note, I have also honed all the washers on the lapping plate, they are all dead flat. I have not had line on the spool yet, but so far, with this configuration, I can feel no break-away to get the drag slipping. It is really smooth. Easily equal to a honed lever drag's smoothness. I am getting around to posting pics as I have time. Still have a fair few more to show.
I'm glad you asked Bryan, because the only reason I could come up with (after I thought about it after I had made this part) was so as not to wear away the edges of the top keyed drag washer, by no longer having the belleville there flexing on it, LOL! I didn't fully think about the Keying of the washers on the gear sleeve. I had it in my head that the top washer beyond the lip of the gear would turn. This clearly isn't the case. The only other reason I can give is if the bridge shaft deflects, under heavy load, the delrin part of the hat, could come in contact with the lip on the
outside of the right side plate. The 20.8mm dimension allows for a clearance of about 0.15mm around this lip.
I'm glad Sal posted the pic of that stack of bricks on the delrin pieces. I weigh 86kg, and would have no doubt, the delrin hat would support my weight without the stainless sleeve. I made the flanged sleeve to stop the possibility of the drag star and sleeve thread deforming the delrin over time by screwing it on/off repeatably, and to transfer the thrust in a uniform manner to the delrin.
That reel, with Rothmar's attention to detail -- should be as smooth as butter when the drag is engaged at start up -- and all of the way to full lock down.
Impressive...
Best,
Fred
I'm hoping so Fred. I probably won't be looking into going for more washers in the drag stack until I've fished it for a while. I think with the honed stock drags it will be more than capable of what I have in mind for it.
Sal, if you think "your not all there", my mates think I'm well gone by spending so much time on a "crappy old Senator". But secretly I think they are all hanging to have a shot with the finished product!
To hell with what others think, I'm having quite a time doing this work, learning a lot about these reels, and myself, as I go.
Quote from: Rothmar2 on October 16, 2014, 09:48:29 PM
I'm hoping so Fred. I probably won't be looking into going for more washers in the drag stack until I've fished it for a while. I think with the honed stock drags it will be more than capable of what I have in mind for it.
Sal, if you think "your not all there", my mates think I'm well gone by spending so much time on a "crappy old Senator". But secretly I think they are all hanging to have a shot with the finished product!
To hell with what others think, I'm having quite a time doing this work, learning a lot about these reels, and myself, as I go.
Don't ever give up my friend, most of us here get it what its all about.
Sal
Chris What a beautiful job!
You are a Genius Chris! I wish I had access to tools like that.
Sal, What are you doing? Is that Stone Mason Jenga? ;)
Quote from: Shark Hunter on October 16, 2014, 10:33:38 PM
Sal, What are you doing? Is that Stone Mason Jenga? ;)
:D :D
Here are some details on the crank/handle
Parts laid out, only thing that hasn't been made by me is the cap head bolt for the handle shaft. (M6mm stainless)
(http://alantani.com/gallery/21/10783_28_08_17_2_53_18_21280986.jpeg)
A few notes. As I mentioned in an earlier post, I was going to order one of the cranks made by Adam or Lee, but I had made a rough crank out of some 3mm flat bar to test mount the handle on. What I noticed straight away there was a significant tipping moment to the right when holding the reel up. I knew right there and then it was going to be back on the lathe to machine out some more weight from the handle. Initially I had drilled 16mm on the long end of the handle, and 18.5 from the top. What I ended up doing was silver soldering a tungsten carbide tool the the end of a own made stainless boring bar in order to dovetail the inside of the handle to remove weight from each end. I also made some accurate depth measurements to get in fairly close to where the shaft sleeve screws into the side of the handle. It was a very tedious couple of hours work to trim down the weight. The handle is now about 2mm thick all the way except for the sleeve socket. It was then I saw one of the Accurate offset cranks on one of Sal's reels and thought that this would be another good move to reduce the tipping moment. I found that 3mm flat was not thick enough for a crank, and the only other flat bar I could get my hands on at the time was 5mm. Ideally I would have preffered 4mm. I would like to say I made a nifty bending jig to get the off set, but no, I did it old school panel beating style....pipes, hammers and a sturdy vice.....and a fair bit of cursing and sweat, but I eventually got the shape i was after. I then drilled 2 holes to shed a bit of weight from the crank, then hand filed the key for the gear sleeve. Finally I drilled and tapped M4 for the locking screw.
It was then onto the belt sander to tidy up all the surface scarring from the forming process (read percussive persuation!). I worked through a few grades of emery, then an air driven buffing wheel (shown when I machined the rings), and ultimately using the little cloth wheels you can get for the Dremels with some Bordo polishing compound to bring out the shine. Fair bit of work involved there. But I like the results. The handle was also given similar treatment.
You can see the delrin bush fitted to the sleeve. This end acts as a bearing of sorts with the shaft nut.
(http://alantani.com/gallery/21/10783_28_08_17_2_57_16_212931892.jpeg)
Grease up the shaft for install. Note another delrin washer under the cap head.
(http://alantani.com/gallery/21/10783_28_08_17_3_22_46_213542311.jpeg)
Install shaft into the sleeve. Grease up the sleeve socket on the handle.
(http://alantani.com/gallery/21/10783_28_08_17_3_26_27_213651141.jpeg)
Screw in the sleeve. (M13 spanner used for the flats filed onto the end of the sleeve.)
(http://alantani.com/gallery/21/10783_28_08_17_3_30_07_213751052.jpeg)
Wind up the shaft nut. A 3.5mm drill was used to put some tommy holes into the side of the shaft nut. The drill acts as a torquing bar. Having this arrangement allows adjustment of the end float of the sleeve on the shaft.
(http://alantani.com/gallery/21/10783_28_08_17_2_54_09_21283151.jpeg)
Place handle shaft through the crank, and wind on the locking nut. Also filed to be 13mm on the flats. Use the drill to hold the shaft nut in position, and tighten the lock nut with the spanner.
(http://i1083.photobucket.com/albums/j393/westozwayward/Mobile%20Uploads/photo_zpsff54569d.jpg) (http://s1083.photobucket.com/user/westozwayward/media/Mobile%20Uploads/photo_zpsff54569d.jpg.html)
And done!
(http://alantani.com/gallery/21/10783_28_08_17_2_58_18_212951486.jpeg)
OK, so here is a bit of view of what its going to look like......
(http://alantani.com/gallery/21/10783_28_08_17_3_16_35_213411840.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_3_07_57_213121193.jpeg)
With this handle, I can trip the clutch lever with my thumb while winding, and bang it striaght into gear.
(http://alantani.com/gallery/21/10783_28_08_17_3_10_38_213221342.jpeg)
Now why I said I was not happy with the first delrin/stainless top hat. With the star screwed onto the top hit with the little spring washer in place, I seem to have a fair bit of thread showing between the handle and the star. Maybe I'm just being pedantic, but I'm thinking of re-making the stainless sleeve for it with a thicker flange at the top, to reduce this gap......mmm maybe later, maybe never.
(http://alantani.com/gallery/21/10783_28_08_17_3_25_19_213611379.png)
Am I finished? No. I still have a problem with the ratchet. The brass rivets that hold the copper ratchet spring are loose, so the whole sping moves, and thus the ratchet is not very consistent sounding, or effective. I have a plan to fix this, will post the solution when I have done it.
Let me say, that reel is a work of art, and I know others have said it, but I can't help myself.
If those ever get mass produced, I'm a buyer, FO SHO! ;)
You've put a lot of hard work into that baby. I don't know if I'd use it if I had put in all that work, but if you do I hope you really nail a winner... you earned it.
Thanks for showing us what lots of skill, access to tools, and passion can do.
Dom
Rothmar,
That Handle is Sick! I guess all the cursing paid off. ;) I can relate.
That has to be the sweetest reel I have ever seen. To boat a monster with that thing would be the most gratifying experience ever!
Nice
The definition of beautiful 8) Well made sir!!
Marc..
Hi Rothmar --
Great work...once again.
I particulary like how you hollowed out the grip ends to reduce outboard weight.
And the way you offset the crank arm more towards the centerline of the reel.
IMO, these two adjustments are critical when landing a fish -- so that there is less side tilt from the outboard weight of the handle -- and better control with your line lay.
Basically, less distraction -- more natural control.
Thanks for sharing!
Best,
Fred
Pure demonstration of why good is the enemy of perfect! every bit of work into that was worth it.
Ron
Thanks again for all the kind words. If I inspire just one person to have a go at doing some of these mods, it would have been worth the journey and effort to post the info here.
QuoteIf I inspire just one person to have a go at doing some of these mods, it would have been worth the journey and effort to post the info here.
There's no doubt you've achieved that!
I can't wait to see the finished reel mounted on a sturdy rod.
Bent over double and Rothmar grinning!
Well done!
I'm going to raise a pint and toast your post?
Thanks for sharing.
Rothmar2 is a genius. ;D
WOW!!! Beautiful reel. Great work. This IS what this site is all about. Thanks for sharing Rothmar2.!
Quote from: Alto Mare on November 25, 2014, 03:47:40 AM
Rothmar2 is a genius. ;D
Errrrr, far from it Sal. I think you might be trying to get the spotlight off yourself here, LOL! Too funny and too kind. I just enjoy having a go at things in life. I have been inspired by many here that are more worthy of the genius title than I am.
Have fixed the ratchet spring problem, and am working on a couple other extra little twists to finish this reel off. I won't be able to show anything until I get home from work in a few weeks time due to Email and data restrictions on the ships satellite system.
David, I have my eye on the rod I want, and already have the PE 5 line to go on it. My main use for this reel will be bottom baiting for striped trumpeter, they can be found from 50-200m water depth depending on locations and time of year. But I also will use this reel for mid sized SBT's, with a topshot of 50lb mono, for when the guys I fish with go on our "tagathon" missions to some remote locations where the fishing can be amazing. The vast majority of the tuna we encounter are in the 30-60lb class, but there is always a chance a genuine "blue cow" could jump on. One of them on this reel will have me looking to install harness lug slots on the inner stainless rings quick smart! For now I'm going to chance it. I'm hoping this will happen on this leave home. Will post a couple of pix of the reels conquests in time.
I'm also building a line-winder ATM. Work in progress. Thanks to those who have posted theirs on this forum. I have been suitably inspired by them all, but Tiddlerbashers is a masterwork I must say.
I'll also get around to finishing off my TLD double dogging post as well, if there is interest, I will make some tools to help with doing this mod for others. It really makes a big difference to these robust little workhorses.
I also have another project I am going to share with you all involving an old Diawa. More on that later.
Quote from: Rothmar2 on November 25, 2014, 10:07:41 PM
Quote from: Alto Mare on November 25, 2014, 03:47:40 AM
Rothmar2 is a genius. ;D
Errrrr, far from it Sal. I think you might be trying to get the spotlight off yourself here, LOL! Too funny and too kind. I just enjoy having a go at things in life. I have been inspired by many here that are more worthy of the genius title than I am.
Have fixed the ratchet spring problem, and am working on a couple other extra little twists to finish this reel off. I won't be able to show anything until I get home from work in a few weeks time due to Email and data restrictions on the ships satellite system.
David, I have my eye on the rod I want, and already have the PE 5 line to go on it. My main use for this reel will be bottom baiting for striped trumpeter, they can be found from 50-200m water depth depending on locations and time of year. But I also will use this reel for mid sized SBT's, with a topshot of 50lb mono, for when the guys I fish with go on our "tagathon" missions to some remote locations where the fishing can be amazing. The vast majority of the tuna we encounter are in the 30-60lb class, but there is always a chance a genuine "blue cow" could jump on. One of them on this reel will have me looking to install harness lug slots on the inner stainless rings quick smart! For now I'm going to chance it. I'm hoping this will happen on this leave home. Will post a couple of pix of the reels conquests in time.
I'm also building a line-winder ATM. Work in progress. Thanks to those who have posted theirs on this forum. I have been suitably inspired by them all, but Tiddlerbashers is a masterwork I must say.
I'll also get around to finishing off my TLD double dogging post as well, if there is interest, I will make some tools to help with doing this mod for others. It really makes a big difference to these robust little workhorses.
I also have another project I am going to share with you all involving an old Diawa. More on that later.
Typical genius, never willing to admit they really are ;D
This is my first time reading this thread and I am amazed..!! It makes me want to go buy machining equipment but I would never have the time to learn.
Wonderful Job..!!
Quote from: handi2 on November 26, 2014, 12:00:21 AM
This is my first time reading this thread and I am amazed..!! It makes me want to go buy machining equipment but I would never have the time to learn.
Wonderful Job..!!
I could do this too but there's a real good reason reels aren't made from wood!
I could do this too but there's a real good reason reels aren't made from wood!
[/quote]
Sure there are wood reels David, and guys still use them(not me lol). google "peetz"
Quote from: Max Doubt on November 27, 2014, 01:51:15 AM
I could do this too but there's a real good reason reels aren't made from wood!
Sure there are wood reels David, and guys still use them(not me lol). google "peetz"
[/quote
" building quality reels of wood and brass since 1925"
And a lifetime warranty to boot,
Not sure I care to experience palming a wooden reel with an albacore on the line! Can you say friction burn!
Quote from: handi2 on November 26, 2014, 12:00:21 AM
This is my first time reading this thread and I am amazed..!! It makes me want to go buy machining equipment but I would never have the time to learn.
Wonderful Job..!!
Cheers Handi2. You can learn to use machining equipment, if I can do it, anyone can. There is so much good stuff on Youtube, and on the web these days. Tubolcaine on Youtube has a whole host of fantastic demo's, and is highly recommended to look up. It really will add an extra dimension to your reel servicing having a few turning skills up your sleeve.
Tonight I completed the reel to where I'm ready to take it fishing. I will post photos when I'm able in a couple of weeks, of the last couple of little tweaks I decided to do.
I would just like to make a few thank you's at this point.
Firstly, to everyone who posts pictures of their Senator builds on here, you have all in some way helped me to visualise where I wanted to take this little project. Please keep it up, its what helps many on here.
To Keta (Lee) for the offer behind the scenes to water pre-cut the rings from the 316 plate. If only I lived closer! A very generous offer all the same. If anyone is contemplating having a go at machining the rings, if you can get access to a water cutter, I thoroughly recommend it!
To Robert Janssen for opening my eyes to lathe spinning. Something I would still like to try some day.
To everyone who offered kind words of support in their posts on this thread, I really appreciate it. Respect to you all.
To Alan C, for his continual ability to make upgrades available for us reel tragics. May you continue to assist pushing the boundaries for these reel's capabilities. I hope its making a few dollars for you, so you are able to continue to make the visions a reality.
To anyone associated with Tiburon here. The frame and spool kits are awesome!
To Scott's Bait and Tackle for their superb overseas service.
To Sal, I really appreciate the guidance you have given me on more than one occasion, behind the scenes.......dunno about the "genius" call though, jury will be gone a long long time on that one! Oh yeah, Daron (Shark Hunter), you put the idea in his head in the first place!!
To Alan T, for sending me the T60NK kit, at a very reasonable price. I hope I have done the kit some justice with what I have shown here. Thank you for one of the best and most informative Forums out there, and keeping this place one of the best to visit on the web.
And to all those who have......."Thanks for reading". I hope I have been able to give you some inspiration for doing some of these sort of things to your own reels. Would really like to see some pix from others who have had a go and modding these classic reels, and breathing new life into them.
Will get some more photos up ASAP.
Awesome thread!
Thanks for taking us along for the ride :)
The Pleasure was all ours! ;)
Hi again. Finally on my way home and am able to add to this thread.
You may have noticed during the course of this that the free-spool lever was slightly bent. This was to allow it to clear one of the side plate screw heads. And it had bothered me somewhat. Here's what I did about it.
First started off with some 5mm 316 flatbar. Centre pop roughly where the centre of the key slot will be
(http://alantani.com/gallery/21/10783_28_08_17_3_04_52_21307336.jpeg)
The goal here is to build a lever with a step to give extra clearance over the side plate screw head. Set the piece into a four jaw chuck and line the centre pop mark up with a dead centre in the tail stock. I also put a parallel block in behind the piece as I was aligning it to keep it fairly true to the tool (good enough in this case). Begin skimming the flatbar to create the step. Drill out the centre at some point.
(http://alantani.com/gallery/21/10783_28_08_17_3_16_12_21338534.jpeg)
I was aiming for a step height a shade over 1mm. Once happy with the height, then trimmed the step diameter to be the same as the original piece.
(http://alantani.com/gallery/21/10783_28_08_17_3_08_05_21313783.jpeg)
Take the piece out of the chuck and align the original lever over the step that's just been machined, and clamp down with a washer and bolt. I used a flat sided needle file to scribe around the original piece to get the shape
(http://alantani.com/gallery/21/10783_28_08_17_3_18_07_213441703.jpeg)
Then while the bolt was still tight, taped off over both pieces, and reclamped with some small vice grips. I could then remove the bolt to scribe out the key-slot.
(http://alantani.com/gallery/21/10783_28_08_17_3_24_16_213582018.jpeg)
All marked out
(http://alantani.com/gallery/21/10783_28_08_17_3_01_03_213001114.jpeg)
Next I had to make a mandrel to mount the flatbar on so I could trim the lever down to the same thickness as the original. Had an offcut from a copper electrode that would do nicely. Drill the centre out to give clearance for the step already machined. Tapped an M6 thread in the flatbar on the scrap end of the piece to help keep it clamped solid.
(http://alantani.com/gallery/21/10783_28_08_17_3_29_51_213742136.jpeg)
Mount back in chuck, align the bolt through the centre of the key slot close enough to centre axis of lathe
(http://alantani.com/gallery/21/10783_28_08_17_3_09_25_213181199.jpeg)
Skim the flatbar down to the same thickness as the original lever, remove from chuck.
(http://alantani.com/gallery/21/10783_28_08_17_3_02_43_213031922.jpeg)
Unbolt the machined piece from the mandrel, punch the location for the top hole, and drill 4mm for the M4 bolt which will be used for attaching the stopper
(http://alantani.com/gallery/21/10783_28_08_17_2_56_10_212892267.jpeg)
Then begin filing the lever to final shape
(http://alantani.com/gallery/21/10783_28_08_17_3_23_24_21356336.jpeg)
Couple of hours of filing and ready for test fit
(http://alantani.com/gallery/21/10783_28_08_17_2_56_21_212901459.jpeg)
Quick check of clearance over the offending screw head, all good
(http://alantani.com/gallery/21/10783_28_08_17_3_00_28_212991370.jpeg)
Then polish the lever and screw up to a high shine
(http://alantani.com/gallery/21/10783_28_08_17_3_06_53_21310390.jpeg)
Now I decided to make the stopper out of Delrin. With the original lever, there was quite a clunk at the ends of travel, and I also was concerned with continual use, that the stopper would get damaged over time.
The Delrin certainly cushions the impact a little, is much quieter, and replaceable with the M4 bolt through it. I put a little locktite on the bolt to secure the stopper.
(http://alantani.com/gallery/21/10783_28_08_17_3_22_33_2135310.jpeg)
You'll notice there is a slight difference in stopper diameter, this in no way affects the engage/disengage of the jack and yoke.
I will post the ratchet spring fix as soon as I get some time.
Very Nice Rothmar!
I can only imagine the metal splinters you get. ::)
Solid Work! ;)
Everytime I see another revival on this thread I end up looking at the whole thread again and it never gets old. Thanks for sharing the making of a true work of art.
Here is what I did to solve my loose ratchet rivet problem. Firstly I used the dremel tool shown in a drill press on high speed to remove the top of the rivet.
(http://alantani.com/gallery/21/10783_28_08_17_3_11_46_21328459.jpeg)
Notice how I have the M3 SS nuts grooved to provide a good hold for the epoxy. These can be done on the drill press with a file. Carefully widen out the recesses until they are just wide enough to take the nuts, and deep enough that the nuts will be flush with the plate. Once happy with this step, mix up some epoxy and fill the recesses about 1/3 full .
(http://alantani.com/gallery/21/10783_28_08_17_3_08_41_213161880.jpeg)
Before embedding the nuts in the epoxy, I smeared a little silicon grease on the threads of the bolts.
Place the nut/bolts into the epoxy, fill any cavities, or scoop away excess epoxy, and allow to cure.
(http://alantani.com/gallery/21/10783_28_08_17_3_27_28_213672169.jpeg)
Once the epoxy has cured, trim down the bolts so they won't bottom out with the copper spring in place.
(http://alantani.com/gallery/21/10783_28_08_17_3_18_12_213452069.jpeg)
Place some loctite (high strength) on nut threads
(http://alantani.com/gallery/21/10783_28_08_17_3_24_31_213595.jpeg)
Bolt in the spring
(http://alantani.com/gallery/21/10783_28_08_17_3_14_43_213341140.jpeg)
Refit the ratchet, and all done
(http://alantani.com/gallery/21/10783_28_08_17_3_05_45_2130911.jpeg)
I will post the finished photos soon.
As always beautiful work! You work has really made me push the limits on fabrication on reels. I have a few in the works. But i can never do the metal work! GREAT job!
Chris, at the rate you're adding parts on that reel, when you're done you will have the complete reel made by you ;D.
I have no doubts, you could build your own reel piece by piece ;).
I would be scared to death doing this to a Newell
Mike
Quote from: Alto Mare on December 29, 2014, 04:53:03 AM
Chris, at the rate you're adding parts on that reel, when you're done you will have the complete reel made by you ;D.
I have no doubts, you could build your own reel piece by piece ;).
If I had access to a milling machine, with a dividing head, rotating base attachment, etc etc etc......I probably would do the whole reel. Probably build myself a complete reel from scratch.
For this particular reel, the only other part I would look into attempting would be the bridge. But for now, I'm going to fish it. Daron, I actually haven't had any more strife with splinters since I did the rings......thank goodness for that!
A few final pix
(http://alantani.com/gallery/21/10783_28_08_17_3_12_40_213291439.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_3_13_02_21330405.jpeg)
(http://alantani.com/gallery/21/10783_28_08_17_2_55_26_212872078.jpeg)
Now to get out and fish it......
Simply amazing!! Great work and truly a one of a kind reel
Stunning, a work of art, it should be in a glass case!
Masterpiece! ;D
Nicely done.
Love this 6/0!!!! I'm really liking the handle arm. Very nice work all around.
Bob
A masterpiece indeed. ;)
Just needs to make that frame out of SS ;)
Cheers guys,
Will catch a few fish on it, then look into whether it needs any further tweaks, do them, and maybe preserve it.
But I feel I owe it to myself to at least hear that ratchet scream in anger.
Truly a masterpiece.
Without seeing the pics & reading the thread, there would be no way to appreciate the time & effort in this reel.
Simply incredible.
dang... you just built a new and improved 3x better Baja Special
Im trying to imagine the fish you might land with that beast. The name
Tank just doesn't do it justice.
I think this reel deserves its own class name.
Super Tank?
Godzilla?
TRex?
Quote from: David Hall on February 09, 2015, 12:33:00 AM
Im trying to imagine the fish you might land with that beast. The name
Tank just doesn't do it justice.
I think this reel deserves its own class name.
Super Tank?
Godzilla?
TRex?
I agree, tank may not be adequate...tank's roll off an assembly line. I think "Thor's Hammer" works better. Little more to say but the implication is appropriate, hand crafted, work of art and lethal.
"We are gonna need a bigger....fish!"
;D
I agree with some of the others, without reading through this whole thread you can't begin to appreciate the time/effort/pure awesomeness of this build. Thanks for bringing us on the journey.
More like, Königstiger (Panzerkampfwagen Tiger Ausf. B) the daddy of all WW11 tanks.
Absolutely superb reel, your work is amazing.
Thanks for the kind words fellas.
I actually only took this reel out for its first full blown trip y'day.
I bought a Penn Torque rod for it, but I wasn't happy with the length of the butt, and had it modified.
Seriously thinking of putting the harness lugs in after I battled this....
(http://alantani.com/gallery/22/10783_13_10_17_2_40_54_220731738.jpeg)
While I didn't use the 6/0 for it, I think it is mechanically capable of beating a fish like this. I will be using this reel to attempt it in the future.
So there may be more posts to come.
I hope someone out there has been inspired to do similar mods to their reels.
Nice Sword!
nice catch
Quote from: Rothmar2 on January 06, 2015, 08:06:35 PM
A few final pix
(http://i1083.photobucket.com/albums/j393/westozwayward/Mobile%20Uploads/photo_zps4367ab53.jpg) (http://s1083.photobucket.com/user/westozwayward/media/Mobile%20Uploads/photo_zps4367ab53.jpg.html)
(http://i1083.photobucket.com/albums/j393/westozwayward/Mobile%20Uploads/photo_zpse7961445.jpg) (http://s1083.photobucket.com/user/westozwayward/media/Mobile%20Uploads/photo_zpse7961445.jpg.html)
(http://i1083.photobucket.com/albums/j393/westozwayward/Mobile%20Uploads/photo_zps51113843.jpg) (http://s1083.photobucket.com/user/westozwayward/media/Mobile%20Uploads/photo_zps51113843.jpg.html)
Now to get out and fish it......
What small quibble I would add (please do not take this as a criticism but something to consider) is that the radius on the outside edge of the reel is not quite in balance with the soft round edges of the frame. I wonder if you could take the radius down a little and improve the feel in the hand??
Regardless, just a tremendous job of craftmanship. *applause*...
No offense taken, it kind of bothered me a little too the radius on the outside rings, but I guess I have just got used to the look of it. The other thing I was worried about was taking a bit too much metal off and possibly weakening the rings. I'm limited a bit with the tool-ling I can access. I just didn't really feel the need to produce a couple of specialised radiused tools just for a set of rings that at the time were probably only going to be "one offs".
IMO, so far while spooling the reel up and tuning, I really don't notice anything negative about how the reel "feels". But then again, I haven't caught a fish with it yet either, so I need to have some real time work with it to have any solid opinion on it.
A Masterpiece!!!
Great Job on that Swordfish! Looking Good! ;D
You should be proud of yourself, not only for creating a work of art but for showing what that "master piece" can do.
Well done and very impressive and thank you for sharing.
Dom
Nice Broadbill. I am really keen to tick one of those off the list. I went out to a local mount on Wednesday(Far north New Zealand). No bites But Geoff Stone on Major Tom (world record holder for Broadbill swordfish) steamed over to ask us if we had caught any Bluenose. I replied "no we were fishing for swordfish" think he was surprised. we were on a 5.6m aluminium boat that was built in 1992. Was good to see him fishing the same grounds as I was only suspecting the area would hold one of these creatures.
well done on your catch and I think the radius on the frame is wrong not your rings.
Best Jon
The wow factor 8)
Marc..
Broke it in today! Despite it being perfect SBT weather, they weren't really on the chew, but did manage 1.
(http://alantani.com/gallery/21/10783_28_08_17_3_01_59_213021075.jpeg)
Unfortunately as it seems to be becoming more commonplace in our waters these days, the seals ruined it somewhat. But did get a couple of belter runs against 8kg of preset drag, enough to feel that the gears will still need a bit more "bedding in".
(http://alantani.com/gallery/22/10783_13_10_17_2_41_12_220751504.jpeg)
Amazingly we were able to wrangle the fish aboard from the sea-dogs without it getting too badly mauled. Didn't have any scales, but would estimate this one to be 30-35lb.
(http://alantani.com/gallery/22/10783_13_10_17_2_46_24_22076770.jpeg)
Hopefully, there will be a few more decent fish to come.
All up, we tagged 3, lost another 3 to seals, pulled hooks on 2, and had a break-off, probably due to a seal.
Anyway, for now, this reel at least shown me what it can do. I think it's capable of much more.
Nice :)
Beautiful Chris! You put in a lot of work in that reel, nice to see you fishing it, looks like its compensating you nicely. ;)
Thanks for the report.
Sal
Great Job Chris. I see you are sporting a Black Magic Fighting Belt . I have to get me one of those.
They are the best made Belt out there.
Glad you got that one from the lions. ;)
Cool!!! Always nice to see a fish caught with a customize reel 8)
Marc..
This whole thread should get the sticky treatment. What an artisan. Kudos! Just amazing!
Andy
Thanks for the generous words Andy.
I've actually done a couple of little mods to this reel in the last year or so. I got told in no uncertain terms that if I ever wanted to try for a sword with this reel, I'd have to get the harness lugs fitted. Sorry to those who loved the "sleek" look.
(http://alantani.com/gallery/22/10783_13_10_17_2_52_50_220772049.jpeg)
Back on page 6 and post #79 I made the comment about the gap between the crank, and the drag star with no pressure on the spacer sleeve. If you look closely, I have made a delrin washer to take up this space.
Actually taking this reel fishing Wednesday. Kicking it old skool. There will be a modified Chinese 114H (extra dog and SS gear sleeve), the Jigmaster 500, and the Tank along as well.
This will be my last attempt with the Tank before sending it back to America. There have been a lot of BFT from 150-280lbs caught lately. Hoping we can hook at least one.
Now this makes it all worth while, seeing them in action.
Hope you get a chance to put the tank on some blood. BFT Shouls do the trick!
Best of luck to you!
:o. Any fishy updates?
Quote from: coastal_dan on January 08, 2017, 11:34:55 PM
:o. Any fishy updates?
Sorry Dan, I've been gloriously uncontactable the last couple of weeks, away on holidays, virtually no internet or mobile phone coverage, bliss!
Last time the reel was fished was in this report.....
http://alantani.com/index.php?topic=15832.150
I was supposed to be going on a day trip with this reel, and the two Jigmasters, two and a bit weeks ago, but the day before I speared myself through the webbing between thumb and forefinger on my right hand when a screwdriver slipped on something tight I was trying to undo. That was me out instantly, but I'm now fine. I needed heavy antibiotics to kill the resultant infection. Still hoping to try and get a sword on it this season.
Thanks for your interest.
Three years goes by very fast . . . Amazing work !!!
Tight Lines !
It sure does! To think the next "project" I have taken on is still not finished.....
Hopefully this reel will get a shot at a sword when I get home in a few weeks.
Thanks for the kind words.
Hi Chris, first time I have looked at this post, great job, truly a talented man, inspiring, thanks for showing us all your magic, hope you get to land a real large fish, you deserve it mate, cheers Don.
Thanks Don, unfortunately I haven't had much opportunity to use this reel the last couple of years. There has been a major upheaval with my work situation, and am not home much these days, so what little time I am home is largely devoted to family. Hoping there is a light beginning to shine at the end of the tunnel, and by next season, I can give this reel much more work.
Wow, I can't believe I'm just now reading this post for the first time. What amazing work! I'm very jealous of 1) your talents and 2) the tools you have available for the job. I'd love to be able to do work like this!
Sid
Of all the reel projects. This one is by far my favorite.
I would love to hold that bad boy. I bet it is heavy.
Chris Don't play. ;)
One of these days, I'll get a weight up for the reel (with line). I did have a set of digi scales, but they suffered electric death, at the hands of my kids (don't ask! ::))
Maybe I'll send it to you Daron for a look see, in the spirit of The Tank's adventure.
Chris, I hate to ask this, but due to Photobucket cancelling our access to your photos, would it be possible for you to re-populate your photos for us to see again? I know it is a big chore, but it would be sad to lose your outstanding work. Bill
Quote from: TARFU on July 29, 2017, 04:34:05 PM
Chris, I hate to ask this, but due to Photobucket cancelling our access to your photos, would it be possible for you to re-populate your photos for us to see again? I know it is a big chore, but it would be sad to lose your outstanding work. Bill
Hi Bill,
Thanks for your interest. I have downloaded my photos from PB, onto a drive. I had almost 700 stored there, most of the pix were then linked to this site. I am just weighing up what to do next, weather to risk Imgur or Flickr and potentially have to go through this all again, or post them to the Gallery here. I'm not able to even look into it for another month anyway, as I'm currently at work (at sea) and am very limited with what I can do from out here. My conumdrum with using the site gallery is I believe I can only have four photos per post, which is going to make redoing this thread even harder if I have to break posts up in order to get the photos in.
I know others have re-built their posts, and I have every intention of doing the same. Its just unfortunate I have probably been my own worst enemy with being too photo-centric with the threads I have done. Its not just the Penn threads I have ahead of me either, there's the Shimano, Banax and Alvey threads (and probably others!) as well. Just have to have the time and place to do it.
Its a bit of a hassle, but once photos are posted anywhere in the forum, you can use forum code to imbed the images in other posts. You could just reply to the original post to attach the pictures, and edit your earlier posts with links to the attached pictures.
Quote from: Rothmar2 on July 30, 2017, 04:36:47 AM
Quote from: TARFU on July 29, 2017, 04:34:05 PM
Chris, I hate to ask this, but due to Photobucket cancelling our access to your photos, would it be possible for you to re-populate your photos for us to see again? I know it is a big chore, but it would be sad to lose your outstanding work. Bill
Hi Bill,
Thanks for your interest. I have downloaded my photos from PB, onto a drive. I had almost 700 stored there, most of the pix were then linked to this site. I am just weighing up what to do next, weather to risk Imgur or Flickr and potentially have to go through this all again, or post them to the Gallery here. I'm not able to even look into it for another month anyway, as I'm currently at work (at sea) and am very limited with what I can do from out here. My conumdrum with using the site gallery is I believe I can only have four photos per post, which is going to make redoing this thread even harder if I have to break posts up in order to get the photos in.
I know others have re-built their posts, and I have every intention of doing the same. Its just unfortunate I have probably been my own worst enemy with being too photo-centric with the threads I have done. Its not just the Penn threads I have ahead of me either, there's the Shimano, Banax and Alvey threads (and probably others!) as well. Just have to have the time and place to do it.
Rothmar,
I am now using IMGUR, but only for images used in forums that require linked images, rather than being able to upload them directly.
Otherwise, I alway upload directly, so that images won't be "lost to the ages", over the years !
It may be possible for the limit on number of images per post to be changed . . . I have seen threads here with MANY more than 4 pic in them, usually Tutorials.
Tight Lines !