Reel Repair by Alan Tani

Conventional and Bait Casting Reel Rebuild Tutorials and Questions => Penn 99/Jigmaster/SurfMaster/Squidder Tutorials and Questions => Topic started by: Rothmar2 on April 30, 2015, 10:51:52 AM

Title: The Jigmaster Project
Post by: Rothmar2 on April 30, 2015, 10:51:52 AM
G'day everyone, got another one on the go. I'd posted somewhere that I would've liked to get my hands on a Jigmaster to do a full make-over on, but hadn't been able to locate one locally at a fair price.
  I got a PM from Mike (mhc) a few days later saying he had one he could send me, and that he'd swap it for a set of 316SS rings, and could I make a second set which he'd pay me for.
For that sort of generosity, the least I could do was do both sets for free!
   Anyway, here it is.


(http://alantani.com/gallery/21/10783_29_08_17_4_13_56_216172149.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_4_30_43_21678632.jpeg)

I'll add, that apart from a little pitting on the spool, and some initials scratched on the left side plate (not Mike's), the reel was in very good condition. Heaps of freespool, smooth drag, immaculately cleaned and greased on the internals. Mike sure knows how to look after his gear.

Anyway onto the rings. I won't go into full details here, as the I have followed the same basic process from the 6/O project.....

http://alantani.com/index.php?topic=10286.0

But will just outline a few subtle differences.
For the left side rings, I have been able to utilize the cut outs from the 6mm SS plate used to make the 6/0 rings

(http://alantani.com/gallery/21/10783_29_08_17_4_32_08_21688492.jpeg)

It's the same process as in the linked thread above. Chuck speed a little quicker than machining the 6/0 rings, due to smaller diametre. I used 180rpm throughout.
Ring machined ready for drilling.

(http://alantani.com/gallery/21/10783_29_08_17_4_17_02_216302189.jpeg)

The right side rings have a bit more to them.
Firstly I needed thicker plate, 8mm, as everyone knows the right ring is wider to fit the locking ring and the side plate. Plus there is a very slight 1 degree taper to the outer ring to help centralize the locking ring.

(http://alantani.com/gallery/21/10783_29_08_17_4_18_08_216321997.jpeg)

So a bit of a sketch of the ring and dimensions were in order.
 Basically the opening for the spool was 61.3mm (sorry child of the metric system here). The ID width of the ring across the flange is 75.5mm and tapers out to 75.8mm. The inner depth to contain the lock ring and the right plate is 6.4mm. The material thickness of the ring is pretty much 1mm all over.
So pretty much the same procedure, except the compound slide for the tool post set for a 1 degree taper (inwards).

Turn out the spool bore

(http://alantani.com/gallery/21/10783_31_08_17_4_03_05_21768935.jpeg)

Scoop out for the locking ring

(http://alantani.com/gallery/21/10783_29_08_17_4_22_30_216441136.jpeg)

Once close, take frequent small cuts and check fit of the lock ring, almost there

(http://alantani.com/gallery/21/10783_29_08_17_4_25_00_216571436.jpeg)

And done. The lock ring should require a bit of a push to seat it correctly

(http://alantani.com/gallery/21/10783_29_08_17_4_28_06_21671702.jpeg)

Reverse the ring on the chuck and tighten outwards. Note mark to keep the ring in same mounting position. You have to meticulously clean all the inside of the ring of swarf, to insure the ring re-mounts flush and true (enough).

(http://alantani.com/gallery/21/10783_29_08_17_4_23_46_216512466.jpeg)

Don't forget to change compound slide angle to taper outward

(http://alantani.com/gallery/21/10783_29_08_17_2_32_44_216022379.jpeg)

Then face off the flange to thickness (1mm)

(http://alantani.com/gallery/21/10783_29_08_17_4_21_25_216402265.jpeg)

And trim the outside edge to give the same

(http://alantani.com/gallery/21/10783_02_09_17_5_04_56_217792317.jpeg)

Remove from chuck, deburr, and ready for drilling

(http://alantani.com/gallery/21/10783_31_08_17_3_46_48_21767675.jpeg)

Still have to make the drilling mandrel yet out of mild steel. I am picking up a 5-40 UNC tap and die set in the next day or so for tapping the hole for the lock screw. Lock screws will be made from SS as well.

In time I'll remake the ratchet, clutch lever, crank, handle (or knob?), etc etc.
Will keep updating as I get it done.

Thanks again to Mike for giving me the opportunity for this project.
Title: Re: The Jigmaster Project
Post by: wallacewt on April 30, 2015, 11:31:16 AM
you,re at it again chris! :D
Title: Re: The Jigmaster Project
Post by: Keta on April 30, 2015, 11:50:05 AM
Very nice!
Title: Re: The Jigmaster Project
Post by: Rothmar2 on April 30, 2015, 12:01:56 PM
Quote from: wallacewt on April 30, 2015, 11:31:16 AM
you,re at it again chris! :D

Again? I never stop.........
Title: Re: The Jigmaster Project
Post by: mhc on April 30, 2015, 01:24:02 PM
Quote from: Keta on April 30, 2015, 11:50:05 AM
Very nice!

x two
Title: Re: The Jigmaster Project
Post by: jigmaster501 on May 01, 2015, 12:56:51 PM
How much are you guys charging for a set of these?
Title: Re: The Jigmaster Project
Post by: bestout on May 01, 2015, 01:05:13 PM
looks nice keep it up :)
Title: Re: The Jigmaster Project
Post by: Penn Chronology on May 01, 2015, 01:27:24 PM
Your level of skill is reminiscent of 1930's craftsmanship, when machinists apprenticed for five years before they were considered journeymen. I am very impressed and will be watching this post religiously. Thank you very much for sharing.
Title: Re: The Jigmaster Project
Post by: fIsHsTiiCkS on May 01, 2015, 08:39:31 PM
Solid work as always!! Any plans to narrow the reel?
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 01, 2015, 09:54:23 PM
Errr, compared to others here, my skills are pretty insignificant really.
But sufficient for "easier" pieces, like rings that can be done on the lathe.
Would really like to learn to use a mill, and be able to afford one. That's another story.....
I will probably look into narrowing this one down the track, but would like to use it first. It was well usable when Mike had sent it to me. After I do this round of rings (3 sets) I'll just put another dog in, and remake the ratchet in stainless, and see how it goes. I will get the SS sleeve in ASAP, but no rush on it yet. Will ultimately get all of Alan C's upgrades in as well.
 To JM 501, not really sure of what I would charge. At the moment each ring has taken about 4hrs work, and I've machined 6, and they aren't finished yet. Remember I'm in Australia as well.......

Got a bit more done last night. Made up a clamp to fix side plate to drill mandrel for transfer punching the hole centres

(http://alantani.com/gallery/21/10783_29_08_17_4_16_28_21628699.jpeg)

Punch the hole centres, this punch was trued on the lathe beforehand

(http://alantani.com/gallery/21/10783_02_09_17_5_22_03_217811092.jpeg)

Very carefully check the alignment of the centre pops before taking to the mandrel with the drills. A mistake here carries over to your rings, and they won't fit, or chew the threads on the side plate screws. 4mm drill for the screw holes, 2.5mm for the locking screw (to be tapped later).

(http://alantani.com/gallery/21/10783_29_08_17_4_25_22_216591514.jpeg)

First of the 3 left plate rings drilled, and test fitted on the side plate.

(http://alantani.com/gallery/21/10783_29_08_17_4_14_23_216192018.jpeg)

Picked up the 5-40 tap and die yesterday. Will probably get onto the right plate rings tonight.
Title: Re: The Jigmaster Project
Post by: Marcq on May 01, 2015, 10:40:15 PM
Bravo!!! I love those  8)

Marc..
Title: Re: The Jigmaster Project
Post by: David Hall on May 01, 2015, 11:15:06 PM
Glad I finished my latest book read last night.  now I can get back here to the good stuff!
Thanks and keep posting.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 10, 2015, 11:17:10 AM
Got onto the right rings a few days ago. Drill speed 250rpm and plenty of cutting oil. No drama with drill burn-out

(http://alantani.com/gallery/21/10783_29_08_17_4_19_37_216361592.jpeg)

Used 2.5mm drill for clearance hole for the 5-40 Tap, no problem there.
Clamp in the lock ring and run taper tap through the threaded hole and into the SS ring. I hope there isn't an issue with thread synchronization for other lock rings, although there is a bit of flex available in the lock ring to help there

(http://alantani.com/gallery/21/10783_29_08_17_4_17_57_216312355.jpeg)

Finish SS thread with lock ring removed

(http://alantani.com/gallery/21/10783_29_08_17_4_12_17_21607998.jpeg)

Also spun up some lock screws. Used 10mm SS rod. Run the knurling tool onto it first as it takes a fair amount of pressure to rough up the surface.
Chuck speed 45rpm.

(http://alantani.com/gallery/21/10783_29_08_17_4_23_13_21647334.jpeg)

Shape the rest of the shank, 3mm exactly to run the die up

(http://alantani.com/gallery/21/10783_29_08_17_4_18_49_21634234.jpeg)

Run up the die, using the tail stock to keep it square, turn chuck by hand with lathe out of gear to get it started

(http://alantani.com/gallery/21/10783_03_09_17_2_43_31_21786963.jpeg)

Part piece off and use belt sander to tidy up any little stub pieces left over

Have almost finished polishing rings. Grits used 240, 400, 600, 800, 1000 lubed with WD40. Then a couple of runs with Autosol. Have some proper SS compound at home and will complete them there.


Title: Re: The Jigmaster Project
Post by: Keta on May 10, 2015, 01:56:51 PM
How many hours do you have in this project?   Your rings are "priceless".
Title: Re: The Jigmaster Project
Post by: Alto Mare on May 10, 2015, 02:34:33 PM
beautiful work Chris! Nice job on the rings, that thumb screw looks amazing as well.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 10, 2015, 03:28:53 PM
Quote from: Keta on May 10, 2015, 01:56:51 PM
How many hours do you have in this project?   Your rings are "priceless".

For just the rings? 25-30hrs and counting. Have made 3 sets at this point. This also includes cutting plate with thin cut-off wheels, pre-machining plates to discs, then parting ring blanks from discs, and actually turning rings to final size, drilling holes, de-burring,making drill mandrel and first stage polishing.
I managed to locate a water-cutter at home, but they wanted $15/ring blank to cut them. I had already tossed up $80 for the 8mm 316 Plate (400 x 400), and still have 6mm plate left over from 6/0 project.
As for lock screws, with lathe set up, 20mins each. Have made a few of varying dimensions, going to get Mike to see what he thinks of them. Trying to make them a little easier to get a decent grip on. Will elaborate later.
As for "pondering" time, with working out what I will ultimately modify, few more hours there.
Have also been making plans to build a SS frame for this as well. I'm using the Daiwa project as the test dummy for that.
Title: Re: The Jigmaster Project
Post by: mike1010 on May 10, 2015, 04:30:21 PM
Beautiful work.  I am in awe.
Title: Re: The Jigmaster Project
Post by: bestout on May 10, 2015, 04:34:21 PM
very nice and interesting
Title: Re: The Jigmaster Project
Post by: Marcq on May 10, 2015, 04:58:50 PM
What can I say, WOW  8)

Marc..
Title: Re: The Jigmaster Project
Post by: Mattman NZ on May 11, 2015, 02:02:44 AM
Excellent workmanship there Rotmar2.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 17, 2015, 06:03:04 AM
So got home a few days ago, and have finished this first little batch off.
Set a calico polishing wheel on my drill, fix drill in vice, and apply some Bordo Stainless Steel compound to the wheel and give the outside surfaces a good buff. Pretty happy with the results after about 10mins/ring.

(http://alantani.com/gallery/21/10783_29_08_17_4_20_14_21638203.jpeg)

Engrave some ID onto the inside face

(http://alantani.com/gallery/21/10783_29_08_17_2_31_02_215951662.jpeg)

Also some fine tidying up on the lock screws on my mini-lathe at home

(http://alantani.com/gallery/21/10783_29_08_17_4_21_34_216411868.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_4_25_09_21658529.jpeg)

A few different subtle sizes for Mike to decide which one he likes, and can knock more up at a later stage

(http://alantani.com/gallery/21/10783_29_08_17_4_21_43_216422450.jpeg)

Mike, will get these off in the Mail this week, let me know how it all goes together for you. Have test fitted them on my JM, no problems.
Be great if you could get a few pix up of your reels with the rings fitted.
Title: Re: The Jigmaster Project
Post by: basto on May 17, 2015, 06:58:20 AM
Very very nice!!!!!  Love your work.
More power to you.
Basto
Title: Re: The Jigmaster Project
Post by: mhc on May 17, 2015, 09:45:33 AM
Another job well done, you've got a lot of talent and the patience to back it up.
I've got an older maroon/brown set of plates and a newer black set to try them on - I'm looking forward to it and will post a few photos.
Title: Re: The Jigmaster Project
Post by: Tiddlerbasher on May 17, 2015, 10:03:44 AM
It's back to lathe school for me :D
Great work Chris.
Title: Re: The Jigmaster Project
Post by: jigmaster501 on May 19, 2015, 12:24:47 AM
Rothmar,

Now that you have mastered the art of stainless jigmaster rings, do you think that you can do these in a sort of mass production run???

Maybe ten sets with those nice locking nuts????

To be honest, the polishing is beautiful but as long as it is functional and burr free, it wouldn't be necessary.

With everyone on here needing your rings, you would have a full time job for sure.....
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 19, 2015, 07:59:59 AM
Good question JM 501. I would be keen to do a run, if I could get onto a CNC machinist who isn't going to charge an arm and leg to produce them.
The hand turning I have shown here is more of a labour of love thing really. I put the detail into the posts I make so that people can maybe follow what I have done to attempt them themselves, should they desire.
I do most of the machining at work, in my own time, after working a full day. I'm a marine engineer, working in a hot environment, and after some days, I just don't feel up to putting in another 6hrs of work to produce these parts in large volumes. I tend to make these bit by bit, doing a couple of hours every other day.
The other limiting factor is I'm a fly-in, fly out worker. There is only so much I can carry to and from work.
Robert Jansen has suggested lathe spinning as an alternative to the full machining as I have shown. I am keen to try it, but I have not been able to track down anyone who knows anything about it to show me how to do it, or the tools required. I believe this would be best way to produce these in quantity. Sadly at this point, I have no knowledge or skills in this technique. I've just conjured these rings purely from what I can currently access.
Title: Re: The Jigmaster Project
Post by: mhc on May 28, 2015, 12:54:20 PM
I have taken a few photo's of Rothmar2's SS rings on a couple of reels.
One is 501 width using newer USA 500 black plates and the other a tiburon framed 500 with older brown/maroon plates.
The rings fit both sets of plates perfectly as you can see in the photos.

(https://lh3.googleusercontent.com/-lfN5tcSim6Y/VWcKNNElsdI/AAAAAAAAAdU/WkpfjLS_r-Q/s800/DSCF2458.JPG)

(https://lh3.googleusercontent.com/-KWSc80Nz-QA/VWcHompzt7I/AAAAAAAAAdI/KC0icNbDvVc/s800/DSCF2454.JPG)

(https://lh3.googleusercontent.com/-J_V8cSFZsXw/VWcEMOQA77I/AAAAAAAAAcc/MfQoBNGNqQk/s800/DSCF2445.JPG)

(https://lh3.googleusercontent.com/-vxG5Lixf_jM/VWb_BLe4r_I/AAAAAAAAAcE/b-lpzv8c58g/s800/DSCF2441.JPG)

Chris also made three locking screws for the removable plate, one sits a bit higher and is easier to grip, the other two sit around the same height as the stock screw and one of the std height ones has a wider knurled area you can see this in the photos Chris posted above. The higher one is easier to grip and is my preference at this stage - without having used them.

Thanks again Chris, your enthusiasm for classic reels shows in your effort and quality workmanship.

Michael

   
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 28, 2015, 08:25:25 PM
Thanks for posting those photos Mike. Sweet looking little reels.
Those handles make them look pretty tough. Are they Kolekar's from Alan T?
Have you put Alan C internals in them by chance?
Title: Re: The Jigmaster Project
Post by: Marcq on May 28, 2015, 08:39:13 PM
Awesome  8)

Marc..
Title: Re: The Jigmaster Project
Post by: steelfish on May 28, 2015, 09:56:58 PM
This is going to be good..
Title: Re: The Jigmaster Project
Post by: David Hall on May 29, 2015, 03:35:20 AM
Beautiful work, lot of love in them rings, I can't wait to see what you do next.
Thanks for sharing.
Title: Re: The Jigmaster Project
Post by: mhc on May 29, 2015, 08:18:23 AM
Quote from: Rothmar2 on May 28, 2015, 08:25:25 PM
Thanks for posting those photos Mike. Sweet looking little reels.
Those handles make them look pretty tough. Are they Kolekar's from Alan T?
Have you put Alan C internals in them by chance?
No problem Chris, you did all the work.
The handle on the 500 is an Alan T SS arm and 3/0 Kolekar grip, the handle on the 501 is a stock 24/56 from Scott's or Alan T.
Yes they both have Alan C SS double dog bridge, yoke, jack, 5:1 SS gear sets and the SS spacer bars on the 501. Alan T SS 98-505 gear sleeves on both & the spool on the 500 is stainless - all we need is a SS stand and star.
Michael
Title: Re: The Jigmaster Project
Post by: fIsHsTiiCkS on June 01, 2015, 09:07:10 AM
Man if we could get SS stars going that would be AMAZING! I would be in for 10 easy.

Great looking rings and reels there, the work Chris does is just stunning!
Title: Re: The Jigmaster Project
Post by: Three se7ens on June 02, 2015, 03:43:12 AM
Quote from: fIsHsTiiCkS on June 01, 2015, 09:07:10 AM
Man if we could get SS stars going that would be AMAZING! I would be in for 10 easy

Ask and ye shall receive. I have a tap for the fine thread, and I found the tap for the coarse thread. And I have nearly 100 drag stars cut. There's a few new designs, and 3 sizes available in each design. I'm working on getting them up on my website and I should have the jigmaster sized stars available by the end of the week.
Title: Re: The Jigmaster Project
Post by: redsetta on June 02, 2015, 08:38:05 PM
Amazing thread - great work Chris!
Title: Re: The Jigmaster Project
Post by: fIsHsTiiCkS on June 03, 2015, 02:47:31 AM
Quote from: Three se7ens on June 02, 2015, 03:43:12 AM
Quote from: fIsHsTiiCkS on June 01, 2015, 09:07:10 AM
Man if we could get SS stars going that would be AMAZING! I would be in for 10 easy

Ask and ye shall receive. I have a tap for the fine thread, and I found the tap for the coarse thread. And I have nearly 100 drag stars cut. There's a few new designs, and 3 sizes available in each design. I'm working on getting them up on my website and I should have the jigmaster sized stars available by the end of the week.

Adam, you are the best!! Just add it to the order you have in for me already!
Title: Re: The Jigmaster Project
Post by: Rothmar2 on June 03, 2015, 08:14:17 AM
Very excited about the new stars as well!
Thanks for the kind words chaps. Will be back off to work soon, and will hopefully advance things a bit further this trip away, and keep you posted.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on July 05, 2015, 12:34:23 PM
Ok, a bit more to update this thread.

I really liked the look off the double ringed Jiggys where the left plate has been swapped from another model (Penn 155?).
 So I decided to do my own take on it.
Firstly I'd have to skim the left plate to have a flat surface to mount the extra ring on
 Mount the plate in the lathe. Note live centre in tailstock and bolt to lightly press against the plate help keep it in place. An alternative could be to use a drawbar through the hollow spindle.

(http://alantani.com/gallery/21/10783_29_08_17_4_16_24_216271145.jpeg)

Lightly skim the landing true

(http://alantani.com/gallery/21/10783_29_08_17_4_27_48_216701731.jpeg)

I actually also decreased the diameter of the logo face a little so as to allow for a little more metal thickness around the screw recesses. The ID of the new ring is 61.0mm. So this spigot needs to match.

(http://alantani.com/gallery/21/10783_29_08_17_4_23_17_21648507.jpeg)

Nice and flat, originally that face was slightly angled

(http://alantani.com/gallery/21/10783_29_08_17_4_14_34_21620968.jpeg)

Here is the new ring, I wanted to maintain the flush mount screws

(http://alantani.com/gallery/21/10783_29_08_17_4_19_54_216371274.jpeg)

And it's the same width as the inner ring

(http://alantani.com/gallery/21/10783_29_08_17_4_17_02_216302189.jpeg)

Seeing as I had the 5-40 UNC tap and die for the right plate lock screw, might as well make my own SS screws for this new ring. The new shank lengths are about 4mm longer than the stock screws. Fresh off the lathe, with stock screws at top

(http://alantani.com/gallery/21/10783_29_08_17_4_27_27_21668410.jpeg)

Hand hack saw in the drive slots

(http://alantani.com/gallery/21/10783_29_08_17_4_13_04_216121745.jpeg)

Bit rough now, but will make them more presentable when I get home to my mini lathe
Left plate assembled

(http://alantani.com/gallery/21/10783_29_08_17_2_31_50_21600150.jpeg)

And a sneak peek

(http://alantani.com/gallery/21/10783_29_08_17_4_14_51_216229.jpeg)

Next thing will be to modify the ratchet. The slider knob will have to have a height increase, with this new ring fitted, its too fiddly to get at. I will be adding an E-clip, and remaking the clicker in stainless as well.
 Still got plenty more twists to do on this build, will get them up as I go.
Title: Re: The Jigmaster Project
Post by: jigmaster501 on July 05, 2015, 01:15:30 PM
Since you are making rings, could you form a harness lug or something that could be fit into the outer ring so you actually have something to hook a jig to. The unless you have a clamp with a hook holder, you are left with hooking the jig to a guide or the handle or something.

These would be great if they could be mass produced.
Title: Re: The Jigmaster Project
Post by: Alto Mare on July 05, 2015, 02:35:13 PM
Can't put a price on your custom parts my friend, you do some amazing work.
Not criticizing, just trying to find out if it would work. Couldn't you have made that left ring larger to go over the existing untouched plate?
The inner cut could have been rounded a little. I wonder how that would have looked?
Thanks for taking us along with your projects Chris...good stuff!

Sal
Title: Re: The Jigmaster Project
Post by: Bryan Young on July 05, 2015, 03:40:45 PM
Amazing.  I like the way the ring protrudes out to protect the bushing and the clicker.
Title: Re: The Jigmaster Project
Post by: Penn Chronology on July 05, 2015, 04:04:01 PM
QuoteCouldn't you have made that left ring larger to go over the existing untouched plate?

That is a very interesting point. In the past, trim rings were made in many different ways and encapsulating the entire rim was one of those ways.

The Pflueger Templar did that;
(http://i380.photobucket.com/albums/oo244/m3040c/Pflueger/EarlyPfeugerTemplar601x927_zps2c2ce392.jpg)

(http://i380.photobucket.com/albums/oo244/m3040c/DSC02052.jpg)

The Holtzmann reels made the trim rings the actual frame, rather than just a reinforcing piece of trim;

(http://i380.photobucket.com/albums/oo244/m3040c/DSC01986.jpg)

And Montague covered the entire side rim also;

(http://i380.photobucket.com/albums/oo244/m3040c/Montague-OCFreeSpool--1.jpg)

          I believe the mods could be endless.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on July 05, 2015, 09:59:03 PM
Thanks for the interest everyone, and always love the history that gets revealed on the forum now too from the ORCA guys. Certainly would like to just see one of the old Templars for real some day.

JM 501, interesting idea re. the hook lug, I might actually look into it for this build down the track. Like I have said before, I'm not really "producing" these rings in any volumes, but if you would like a set, send me a PM, and we can work something out from there.

Sal, I agonized over the rounded edge on the ID of the solid ring. I could have maybe machined the spigot in a little further, and made the ring a little wider, but felt that it might have encroached too close to the clicker button. If I radiused the ring I made, it would also have crept onto the screw recesses, and could have left a sharp edge here.
The wider ring is an interesting idea, but I would need to start with SS plate about 5/8" thick, which I currently don't have. I've got a 349 project coming up, and was able to use the cut-out from the 6mm plate blanks for the 349 rings, to make this extra ring for the Jiggy. But, your idea would would look very slick! In its current form, it gives the reel a pseudo-senator look.

Bryan, you'll probably lynch me after I do the clicker button remake! ;D
Title: Re: The Jigmaster Project
Post by: mhc on July 06, 2015, 10:09:11 AM
Inspirational stuff again Chris. That reel is looking like a pretty substantial 500 with those rings - I can't wait to see what you come up with next.
BTW are there aluminum covers on the 6 inch(?) vice to protect the screws while you cut the slots?
Mike
Title: Re: The Jigmaster Project
Post by: Rothmar2 on July 06, 2015, 12:17:00 PM
Yes Mike, ally soft jaws. Use copper too at times, particularly when rechucking parts on the lathe where I might have given them some finishing treatment, but will use copper in a vice as well.
Don't bother with plastic soft jaws, use-less!
Title: Re: The Jigmaster Project
Post by: basto on July 07, 2015, 12:05:32 AM
Wow! Very classy stuff. Reminds me of a squidder now. If you put two rings on the right plate, it would look like a 3/0 Senator.
best regards
Basto
Title: Re: The Jigmaster Project
Post by: coastal_dan on July 14, 2015, 08:58:37 PM
Thoroughly enjoying this build!
Title: Re: The Jigmaster Project
Post by: Jerseymic on July 14, 2015, 09:24:42 PM
It is a pleasure to see a master craftsman at work, stunning.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on August 07, 2015, 02:59:16 AM
Hi Everyone, bit of an update on this project.

I recently made a faceplate for my mini lathe while at work. The motivation was to allow for a little more scope for me to produce parts from home.

Jigmaster 501 (Eugene) had asked about a lug to be made for the left plate in which a lure could be attached to when the rod was racked. Having the faceplate allowed me to come up with something......

(http://alantani.com/gallery/21/10783_29_08_17_2_31_12_21596152.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_4_32_13_216891076.jpeg)

....a blank to shape the lug from. You can see from the machining pattern how I have used the faceplate and a dead centre to align the blank to turn down the little spigots which will locate in the left plate holes.

I also faceplate machined in the radius for the step on the left plate, and then rough shaped the lug

(http://alantani.com/gallery/21/10783_03_09_17_4_04_58_217871542.jpeg)

Some shots with rough shaped lug fitted

(http://alantani.com/gallery/21/10783_29_08_17_4_32_23_21690422.jpeg)

(http://alantani.com/gallery/21/10783_03_09_17_4_13_23_217891598.jpeg)

I will do final shaping and polishing when next away at work.
I will also be making a couple of ring sets for Eugene as well while away.

At risk of sounding a bit selfish, after I have done these parts, I won't be taking orders for making any more for a while. I don't have enough spare time to devote to making them for others. I haven't made enough progress on my own Jiggy lately to feel like it will be ready for next season. The only person I will be working with/for will be Mike (mhc) who has helped me out in a huge way behind the scenes.

I have also made a start on the SS ratchets. The SS shifter on the left, and original on the right

(http://alantani.com/gallery/21/10783_29_08_17_4_29_19_216731618.jpeg)

I am going the E-clip route with these. You can see with the ratchet blank I have machined a couple of recesses the thickness of the E-clip into the stock. This should prevent any rubbing of the new arrangement against the side of the spool. It will be clear what and why  I have done this when I have all the parts ready for assembly. Should have something to show again in a few days time.
I have also increased the size of the shifter knob, as the original is a bit fiddly to get a decent push/pull against.
The first few of these will be going to Mike, I'll then make one for the left plate of my JM which will need to be larger again due to the extra ring on the left plate.

More to come soon.
Title: Re: The Jigmaster Project
Post by: redsetta on August 07, 2015, 07:15:37 AM
It's like magic  ;)
Looking forward to the next instalment!
Title: Re: The Jigmaster Project
Post by: Rothmar2 on August 09, 2015, 10:19:18 AM
Got the ratchets done over the last couple of days. These ones will be going to Mike which will drop straight into any Jigmaster. I'll show the one to suit the extra ring when I get it done.

Couple of hours filing to get the shape.

(http://alantani.com/gallery/21/10783_03_09_17_1_05_41_217901472.jpeg)

Then machine some delrin washers to slip in under the ratchet to reduce wear on the plate. Turn down 12mm stock to 10.5mm. Centre drill stock, and drill bore 5mm. I made a parting off tool to hold a broken hack-saw blade to cut the washers. The thin blade greatly reduces wastage.

(http://alantani.com/gallery/21/10783_29_08_17_4_14_09_21618917.jpeg)

I made a few of varying thickness to get a good fit with minimal slop of the ratchet. The E-clip is part no. 69B-600.

And all together

(http://alantani.com/gallery/21/10783_29_08_17_4_35_37_217041748.jpeg)

Looking from outside, all polished up. This shifter is about 1.5mm taller than stock. Bit easier to get a decent purchase on it.

(http://alantani.com/gallery/21/10783_03_09_17_1_17_31_217911155.jpeg)

Nothing magic here Justin, just getting in and having a go.

Thanks for everyone's kind words.
Title: Re: The Jigmaster Project
Post by: mhc on August 09, 2015, 11:55:03 AM
Looks good Chris, this project keeps getting better.

Quote from: redsetta on August 07, 2015, 07:15:37 AM
It's like magic  ;)
Looking forward to the next instalment!

I'm with Redsetta on this one, there is a difference between simply getting in and having a go and successfully turning (pun intended) your ideas into reality.
Title: Re: The Jigmaster Project
Post by: Alto Mare on August 09, 2015, 12:50:20 PM
Quote from: mhc on August 09, 2015, 11:55:03 AM
Looks good Chris, this project keeps getting better.

Quote from: redsetta on August 07, 2015, 07:15:37 AM
It's like magic  ;)
Looking forward to the next instalment!

I'm with Redsetta on this one, there is a difference between simply getting in and having a go and successfully turning (pun intended) your ideas into reality.
I agree!! This man has some serious talent, making your own parts is not the same as purchasing what you need.
Thanks for sharing your projects with us Chris, its very much appreciated. ;)
Sal
Title: Re: The Jigmaster Project
Post by: Penn Chronology on August 09, 2015, 03:27:17 PM
QuoteNothing magic here Justin, just getting in and having a go.

It not about magic, it is about seeing something in your minds eye and then being willing to do what is needed to bring that dream image into the real world. You missed your calling Sir, you belong in the Penn Engineering Department designing prototypes!
Title: Re: The Jigmaster Project
Post by: mhc on September 02, 2015, 09:50:33 AM
And then all together on a 501 with SS rings, spacer bars and take apart thumb screw. Thanks Chris!
I tried putting the delrin washers Chis made under the ratchet and then under the shifter - under the shifter seemed to slide a bit smoother.

(https://lh3.googleusercontent.com/-YWfL-Aajyuc/Vea4O8E6yfI/AAAAAAAAAiQ/IB9YS1tnhac/s800-Ic42/DSCF2508.JPG)

When assembled, the ratchet is firm and loud as I requested although it occasionally slipped out of engagement. I will need to gently and slowly put a steeper shoulder on the back half of the ratchet for the spring to grip. I'll wait until I get a suitable needle file for the job and not use my chainsaw sharpening file.
(https://lh3.googleusercontent.com/-2JHYrqu07t4/VdWnLnF0UuI/AAAAAAAAAhg/8mGdaMRNddQ/s800-Ic42/DSCF2505.JPG)

(https://lh3.googleusercontent.com/-K7ai-FU1iy4/VdWmejtN1dI/AAAAAAAAAhA/q-QKFwWtht0/s800-Ic42/DSCF2510.JPG)

To remove the old clicker I simply drilled out the back where it is peened

(https://lh3.googleusercontent.com/-03n-G6J-D7E/VdWnh7VcFSI/AAAAAAAAAhw/AYTAWFArPz8/s800-Ic42/DSCF2502.JPG)

My first attempt at removing the ratchet was memorable - I thought I had removed more than enough material with the drill but the clicker still wouldn't lift off. In an absent minded moment of madness, I put the plate on top of a vice and gave the ratchet shaft a light tap with a punch  :-[ - keep this to yourself, I don't want anyone to find out ;D.
I'm now in the market for a black left plate.

(https://lh3.googleusercontent.com/-r1R3eYSoh2g/VeayUboDzVI/AAAAAAAAAiA/pvP2wGD6luQ/s800-Ic42/DSCF2511.JPG)
Title: Re: The Jigmaster Project
Post by: exp2000 on September 02, 2015, 10:32:32 AM
Quote from: Alto Mare on May 10, 2015, 02:34:33 PM
beautiful work Chris! Nice job on the rings, that thumb screw looks amazing as well.

X2
~
Title: Re: The Jigmaster Project
Post by: Rothmar2 on September 02, 2015, 10:29:33 PM
Mike, I'm so sorry you snapped that left plate.  :o I feel partly responsible.....
Will work something out when I get home in a few weeks.
With the ratchet, how was it disengaging? Was the shifter getting pushed back, or was the copper spring riding up and over the ratchet? The spring on my plate which I tested it on, is a little loose, and this happened a couple of times. I won't be looking for as much ratchet tension when I get around to doing mine, and as you have rightly pointed out, the shoulders are where I'll be carefully filing to adjust. I did similar on the 6/0 build, and also carefully notched the end of the copper spring.
I'm really gutted you snapped that plate but.....

Just had a close look and your pix Mike, I wonder if there isn't a very subtle difference in the copper spring diameters? If you look at the assembled photo I posted against yours, it appears as though your spring doesn't "reach" onto the ratchet as far as what my copper spring does. Could be just a photo angle/perspective thing though.
Title: Re: The Jigmaster Project
Post by: Alto Mare on September 03, 2015, 12:04:58 AM
I checked and only have the red in pairs, sorry.
Try here, this one needs help, but usable
http://www.ebay.com/itm/Vintage-PENN-Parts-Jigmaster-500-Fishing-Reel-PART-Left-Side-Tail-Plate-PLATES-/151789580501?hash=item23575d30d5
This one looks better, he'll probably let you have it for $14:
http://www.ebay.com/itm/USED-PENN-CONVENTIONAL-REEL-PART-Jigmaster-501-Left-Side-Plate-E-/351485148457?hash=item51d625bd29
Title: Re: The Jigmaster Project
Post by: mhc on September 03, 2015, 08:29:37 AM
Thanks for checking Sal - the plate in the 2nd link looks good, I'll have a look to see if he has anything else I need to spread the shipping costs a bit. I have bought parts from him in the past and he has always been good to deal with.

Don't feel responsible Chris - it was entirely my fault. I had been off work with the flu for a few days and thought I was feeling better - went down stairs, broke the plate then went back to bed. I should have listened to my doctor when he said 'take it easy'   ;D ;D

The shifter is getting pushed back, not every time and not straight away so it shouldn't take much to hold it. I'll mark where the spring sits and take it from there.
The photo above is with the clicker in the disengaged position, here's one below with it pushed in. I'll measure the springs on the other black plate and a couple of red-brown ones I've got to see how consistent the diameter is.

(https://lh3.googleusercontent.com/-cMut6zoK5RA/Vef-IpLiouI/AAAAAAAAAig/EFKwVIRPUSQ/s800-Ic42/DSCF2512.JPG)
Title: Re: The Jigmaster Project
Post by: Rothmar2 on September 16, 2015, 11:25:10 AM
Mike, my bad with the pics and not picking the engage/disengaged position of the shifter.
Have you had a chance to modify the clicker further to stop it jumping out? They can be very touchy those, doesn't take a whole lot of metal removal to drastically change their characteristics.

On another note, have finished shaping Eugene's requested side lugs. Not completely consistant in shape, had a bit of a slip-up while turning the blanks on the mini-lathe, but still finished up with two workable pieces.

(http://alantani.com/gallery/21/10783_29_08_17_4_31_05_21681788.jpeg)

Just have to make some custom SS screws to suit and polish these parts up. Will put up an assembled photo later
Title: Re: The Jigmaster Project
Post by: mhc on September 16, 2015, 01:17:20 PM
Quote from: Rothmar2 on September 16, 2015, 11:25:10 AM
Have you had a chance to modify the clicker further to stop it jumping out? They can be very touchy those, doesn't take a whole lot of metal removal to drastically change their characteristics.

Not yet Chris, Still a bit busy and don't want to rush it and like you said, it can be touchy. I have another plate on the way and will sit down and fine tune both of them when I'm not distracted.
Those lugs look good - with all the upgrades to jigmaster gears, drags and bridges etc that are happening, you might have to find a way of putting them on the top of the reel as harness lugs!   
Title: Re: The Jigmaster Project
Post by: Rothmar2 on September 24, 2015, 10:20:01 AM
I have made a start on a SS frame for this reel.
  Please note, this is no-where near completion, but I have come far enough at this point to prove the concept.

 Here's where it's at...

This started a couple of months ago on my last trip away. I built a punch/die set to bend 8mm SS plate into a blank that could be machined into a frame

(http://alantani.com/gallery/21/10783_29_08_17_4_12_34_216081591.jpeg)

Then this trip I have been able to make some progress, but for now I have run into a brick wall (more on that later).

True'd up a piece of plate prior to bending. It's about 5mm wider than finished width to leave plenty of room for machining down later. The 4 holes were drilled in case I needed them later to pull the blank around further. As you will see, they weren't needed, nor would they have worked anyway,  as the plate length was not long enough. It was an offcut piece from pre cutting the 8mm Jigmaster right plate rings.

(http://alantani.com/gallery/21/10783_29_08_17_4_27_13_216671423.jpeg)

Set it up on a 20 tonne press. Note the shim steel (0.5mm) between the punch and plate, and between die and plate. These shims were allowed for in calculations for the punch diameter and die gap. I made them to act as a buffer between the mild and stainless. All surfaces are greased prior to pressing.

(http://alantani.com/gallery/21/10783_03_09_17_1_56_15_21793183.jpeg)

In it goes....

(http://alantani.com/gallery/21/10783_29_08_17_2_31_45_21599797.jpeg)

I soon realised the die needed further re-inforcing, about 1/2 way in and the right edge of the die begins to bend and buckle. So a couple of end pieces were hastily cut and welded to the die, befor re-trying.

(http://alantani.com/gallery/21/10783_29_08_17_4_26_58_2166644.jpeg)

Eventually got it all the way down.

(http://alantani.com/gallery/21/10783_29_08_17_4_12_53_216111907.jpeg)

But the sides of the bent piece were no where near parallel....might have to build up the sides of the die if/before attempting to make another.

So removed the punch/plate from the die, reclamped the pieces together with a G-clamp and was able to get some extra bending done on a vice.

(http://alantani.com/gallery/21/10783_29_08_17_4_28_50_21672845.jpeg)

But the 4 holes I drilled in the plate to squeeze it around further weren't going to work (ie plate piece too short).

So break out the oxy to heat the plate and bend a bit further around by squeezing the ends in the vice jaws.

(http://alantani.com/gallery/21/10783_29_08_17_4_27_35_21669889.jpeg)

Once I was confident I had bent the plate far enough, I heated the whole lot up with a propane burner for about an hour to equalize the temperature before quenching in a large bucket of water. This was done as a sort of attempt to relieve stress from bending. To do this properly, you would have to heat the entire piece to 1050 degs before quenching, but a partial anneal can be done quenching from around 380degs, which I was able achieve here.

(http://alantani.com/gallery/21/10783_29_08_17_4_30_59_216801449.jpeg)

Once the assembly was cooled I was able to remove the bent plate, by detaching one end of the punch, which was held on by a M16 HT cap head bolt.

(http://alantani.com/gallery/21/10783_29_08_17_4_23_32_21650626.jpeg)

Quick check that all side plate holes have stainless underneath them, all good.

(http://alantani.com/gallery/21/10783_29_08_17_4_22_55_216461736.jpeg)

Next up I had to make a jig for drilling the holes. I started off by cutting three pieces of 85x85x10mm mild steel and tack welding them together flat on top of each other. Then find the centre, and mark out the position of two other holes, one that will lie inside the rough shaped frame, and another out near the open part of the frame.
The centre hole was drilled 10mm and the other two 6mm. This was done while the 3 pieces were together so to insure these 3 location holes would be identical on all three plates. The left end plate was then mounted over the centre hole with a special made draw clamp to keep it centalised, and the frame holes were  transfer punched to the stacked plates. The 6 holes were drilled through the plates with a 2.5mm drill (major mistake). I then mounted these 3 joined pieces on the lathe and used a length of M10 all thread as a drawbar through the self centering 3 jaw, and then machined the plates down to discs (similar as to what I do when making the SS rings).
The positioner rods were made from diesel injector push rods (scrapped parts after some overhauls) and modified so the butt end press fitted into the 6mm location holes. Finally one plate was skimmed to form a slight ridge , which was ever so slightly under the rough ID of the frame.
 The finished jig....(sorry about lack of jig fabrication pics...I was on a mission!)

(http://alantani.com/gallery/21/10783_29_08_17_4_15_10_216231214.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_4_15_19_216241552.jpeg)

Before going ahead and drilling the frame holes, the rough frame was mounted in a 4-jaw chuck to flatten the end edges of the frame. The plate does warp a bit from the bending and heat forming process. This was done to make sure the drills had a flat contact surface.
  Set the frame into the jig, and mount the jig onto the drill stand with a clamp kit. All critical drilling has been clamped during the course of this project. It's the only way to maintain (reasonable) accuracy.

(http://alantani.com/gallery/21/10783_29_08_17_4_20_52_2163976.jpeg)

And pattern drilled into the ends....

(http://alantani.com/gallery/21/10783_29_08_17_4_21_52_216432094.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_4_30_18_21677322.jpeg)

Now this is where it has gone pear shaped. Next step was the set one end as a datum, and tap the holes 5-40 UNC, so I could bolt the rough frame to a faceplate (the 3rd piece of steel drilled) so I could machine the frame to the correct width.
 My mistake drilling the clearance holes 2.5mm soon revealed itself, yep you guessed it, broke the taper tap after 1 1/2 holes. Fortunately it broke above the hole edge and I was easily able to get the remains out.
 When I checked the Machinery Handbook afterwoods, it mentions not tapping 316 SS with taper taps as the finer entry of the tap workhardens the chip, and causes excess load to these small taps.....yes that's true. They recommend intermediate and plug taps only. I also checked the clearance hole diameter and it should be 2.6mm. That 0.1mm surely must make a difference. As this was my only tap, things have now come to a halt until I'm next back to work in about 6 weeks.

I already have plans for the reel foot, but will reveal that later.

Still no garentee that it will work. First litmus test will be when all the holes are tapped, and I can test fit the spool and side plates.

But the bending/ machining concept I think can be achieved, just need to get this first frame to full completion to prove it. See what happens in 6 weeks time.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on September 24, 2015, 10:36:22 AM
There seems to be a bit of a problem with the photobucket links, I have no idea why some photo's have doubled up, I am trying to fix this....

Edit - Fixed!!
Title: Re: The Jigmaster Project
Post by: ReelCurious on September 24, 2015, 02:13:04 PM
I have to say, this is a fascinating project.  Good job to you.
Title: Re: The Jigmaster Project
Post by: Alto Mare on September 25, 2015, 10:45:11 AM
Chris, I'm always amazed by your skills, thanks for sharing your projects with us.
I just stickied it, I don't want this thread to disappear.
Great job!...keep it alive.

Sal
Title: Re: The Jigmaster Project
Post by: Rothmar2 on September 25, 2015, 11:15:32 AM
Thank you Sal, I'm honored by your gesture.
I will keep this alive if the interest is there. But this thread is likely to go a fair bit longer than the 6/0 project. My twisted head keeps coming up with more things to try.
I hope some are inspired by what I put up. It also helps me as something to go back to if I get a "how did I do that?" moment.
Thanks for having me here.
Title: Re: The Jigmaster Project
Post by: Penn Chronology on September 26, 2015, 01:21:24 AM
QuoteI will keep this alive if the interest is there. But this thread is likely to go a fair bit longer than the 6/0 project. My twisted head keeps coming up with more things to try.

A pleasure to watch you work.
Title: Re: The Jigmaster Project
Post by: Rancanfish on September 26, 2015, 02:20:13 PM
Mr. Chris,  Are you kidding? Of course there is interest. I was sitting here in a dark kitchen having a cup of my morning coffee, when I realized I just said 'Wow', right out loud!  ;D

I am envious of your trade skills.
Title: Re: The Jigmaster Project
Post by: mhc on September 27, 2015, 11:46:11 AM
Hi Chris, I'm always impressed with your innovation and attention to detail, particularly the thought and effort you put into preparation with jigs etc, it's extraordinary. Will the process you are developing work with aluminium as well? I think it has potential for stands as well as half frames. 
Title: Re: The Jigmaster Project
Post by: mhc on October 05, 2015, 05:37:28 AM
Hello Chris, I finally got around to modifying the clicker to stop it jumping out. I gave the clicker tongue a few strokes with a 1/8" round file on each side to sharpen the 'shoulder'. Like you said, it didn't take much and now stays engaged.

(https://lh3.googleusercontent.com/-pjZo2xl1VQ8/VhIFflGJXWI/AAAAAAAAAjU/htccTqIWrHo/s800-Ic42/DSCF2514.JPG)

(https://lh3.googleusercontent.com/-An31PaM3Fsk/VhILiIks6qI/AAAAAAAAAjs/wzW0GxEoSu4/s800-Ic42/DSCF2515.JPG)

The recess where the ring sits on the replacement plate I picked up was a slightly larger diameter than the one I broke and the SS ring would not fit. I didn't want to force it so I ran a triangular file around the recess to make it a firm fit - again it didn't take much.

(https://lh3.googleusercontent.com/-0Sq4pdBCNUw/VhIFvxaD1HI/AAAAAAAAAjc/2ZH4k5w6nko/s800-Ic42/DSCF2513.JPG)
Title: Re: The Jigmaster Project
Post by: Rothmar2 on October 09, 2015, 02:32:04 AM
Hi Mike,  Sorry I haven't replied sooner, I have been pretty knocked out with the flu the last week or so.
Am glad you have been able to sort the ratchets out. Funny how there is always a few little subtle differences with the side plates, at least you have been able to get around that one as well.

I have finished Eugene's parts. Completed lugs, 2 sets of SS rings, with screws and 2 pcs right sideplate lock screws. I hope you like them Eugene!

(http://alantani.com/gallery/21/10783_29_08_17_4_41_47_21725965.jpeg)
Title: Re: The Jigmaster Project
Post by: jigmaster501 on October 10, 2015, 09:07:49 PM
That looks like some beautiful work right there.

I will throw those on 2 reels with Tiburon frames and make beast reels...

Title: Re: The Jigmaster Project
Post by: Dominick on October 11, 2015, 12:23:46 AM
Hey Rothmar, that work deserves a big WOW from me.  Beautiful work.  Dominick
Title: Re: The Jigmaster Project
Post by: steelhead_killer on December 16, 2015, 07:01:00 PM
Unbelievable work!  Where was I when they were handing out talent like that?
Title: Re: The Jigmaster Project
Post by: thorhammer on December 16, 2015, 07:13:43 PM
just saw this....WOW. I'm happy to get two 2x4's screwed squarely. what a skillset!!!!! not to mention some cool toys to work with.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on December 17, 2015, 07:02:47 PM
Thanks for the generous words guys. I assure you this thread has not died, just stalled due to some admin trouble from work. In the meantime I have been procuring parts and tools to continue.
I have Alan C's gears, bridge, jack and yoke ready to go. Mike obtained a bunch of UNC taps off EBay, that included a box full of 5-40's and has sent them to me. I have purchased a box of cobalt-moly 2.6mm drills, so once I'm back to work mid-Jan, this thread will liven back up.

Title: Re: The Jigmaster Project
Post by: Rothmar2 on January 17, 2016, 10:39:26 PM
OK, so back at work and have been able to make some progress again.
2.6mm drills and extra taps procured to be able to continue

(http://alantani.com/gallery/21/10783_29_08_17_2_29_04_21589416.jpeg)

Drill out all holes from both ends of the rough frame with 2.6mm drills

(http://alantani.com/gallery/21/10783_29_08_17_4_25_48_21660762.jpeg)

And finish tapping the holes at my datum end

(http://alantani.com/gallery/21/10783_29_08_17_4_33_11_21692473.jpeg)

Made up a plate to mount the frame on (actually the 3rd plate drilled from when I made the drilling jig). It has been skimmed at one end to be square, the datum end of the rough frame will bolt to this. Bolts are M8 cap heads turned down and re-threaded 5-40 UNC.

(http://alantani.com/gallery/21/10783_29_08_17_4_42_36_21730621.jpeg)

Bolt up and mount on lathe. The collar behind the mounting plate was trued up beforehand. I did this so I could check on the tightness of mounting screws, I figured they would work loose from the vibration of the intermediate cuts. The plate is held in place with  M10 thread bar clamped in the chuck, and a nut do draw it hard against the chuck. The dial gauge was used to get it all running reasonably true.

(http://alantani.com/gallery/21/10783_29_08_17_4_45_13_217459.jpeg)

Aiming to turn this down to the width of the stand

(http://alantani.com/gallery/21/10783_29_08_17_4_44_00_21740890.jpeg)

First trim it to the stand width using facing cuts

(http://alantani.com/gallery/21/10783_29_08_17_4_31_52_216871520.jpeg)

Had to frequently check the holding bolts. I'll add that to true this frame down took about 5 hours of work. I was only able to take very fine cuts, max 0.15mm at a time, I wasn't overly confident in the holding ability of the re-threaded mounting screws.
I used a chuck speed of 375rpm, seemed to give a good result.

(http://alantani.com/gallery/21/10783_29_08_17_4_34_14_21697683.jpeg)

Then bore the inside of the frame

(http://alantani.com/gallery/21/10783_29_08_17_4_43_50_21738891.jpeg)

I stopped when I was getting worried that I was approaching too close to the frame holes. A quick check of the spool diameter confirmed I had enough clearance in the bore.

(http://i1083.photobucket.com/albums/j393/westozwayward/Mobile%20Uploads/photo_zpsxnxkxxoa.jpg) (http://s1083.photobucket.com/user/westozwayward/media/Mobile%20Uploads/photo_zpsxnxkxxoa.jpg.html)

Skim down the outside of the frame.

(http://alantani.com/gallery/21/10783_29_08_17_4_31_52_216871520.jpeg)

And all cleaned up after 5hrs!

(http://alantani.com/gallery/21/10783_29_08_17_4_24_41_216562286.jpeg)

Unbolt from the chuck plate and clean out the trimmed end holes with the 2.6mm drill.

(http://alantani.com/gallery/21/10783_29_08_17_4_34_09_21696931.jpeg)

Just tapped 3 holes for the trial fit, no point doing them all until I could confirm that this would actually work....

(http://alantani.com/gallery/21/10783_29_08_17_4_38_50_217171601.jpeg)

Plates mount on OK.....

(http://alantani.com/gallery/21/10783_29_08_17_2_30_49_215942368.jpeg)

And the spool spins without catching!

(http://alantani.com/gallery/21/10783_29_08_17_4_23_56_216531108.jpeg)

So, I'm pretty happy to have made it this far. Still much more to go......
Title: Re: The Jigmaster Project
Post by: Alto Mare on January 18, 2016, 01:07:52 AM
Can't say enough about this Chris, it's like watching a great tv series.
I'm enjoying the ride...thank you!

Sal
Title: Re: The Jigmaster Project
Post by: Cortez_Conversions on January 18, 2016, 03:15:00 AM
Looking good Chris!
Title: Re: The Jigmaster Project
Post by: thorhammer on January 19, 2016, 07:23:29 PM
In awe of this process and skillzzzzz. It's not so long ago that my own thread titled "Jigmaster project" would have been a picture of swapping in a red anni spool with the quick take apart, lol.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on January 19, 2016, 10:37:23 PM
Thank you Sal, I hope this is "keeping it real" more so than some of the tripe that is on Discovery Channel lately  ;D. Tom, while it all looks good on here, I have some confessions to make. This first frame will only work with the Bakelite plates. There are 2 holes (for the posts) that are just shade off. I will be able to carefully recover that with some modifications to the SS rings and plate bores. Seeing as I have a set of your plates coming, I'll have to redo the drilling jig with your plates as the template. I think where the error has come, was a couple of the holes were not perfectly true round in the Bakelite plate, and when I transfer punched the centre pops, the punch possibly could not have been located correctly. As you well know that's all it takes sometimes..... >:(. I had a SNAFU with one of the 2.6mm drills. It snapped about 5mm off the end. I was able to break most of it out by using a stainless roll pin with an extra slot filed to grip the flutes and break about half of it out. I figured with the last bit I couldn't get, I just punched it into the base of the hole and will forget all about it  >:(. I wish I had an EDM though......
I have finished tapping the rest of the frame holes without incident. It was still a slow tedious process.
Going to bend up a couple of 501 width frames next. Will have to make up some spacing collars for the punch/die first. Once I have a few frames prepped I'll decide what I am going to do with the reel seat. This is proving to be a "reel conundrum" as I don't have access to a mill. I had an old gentleman who had a mill in has shed who was willing to help me with this project, but he has been unwell for a fair few months now and things aren't looking great in the near future. His advice and guidance has been a big part in making it this far.
 Thanks again for your interest everyone, will keep getting more pix up when I can.
Title: Re: The Jigmaster Project
Post by: David Hall on January 20, 2016, 01:41:42 AM
Sure hope the network doesn't cancel this series.
I love it.
Title: Re: The Jigmaster Project
Post by: Shark Hunter on January 20, 2016, 06:04:21 AM
Awesome Work Chris.
Title: Re: The Jigmaster Project
Post by: mhc on January 21, 2016, 12:39:23 AM
My respect for your work keeps growing with this project. To quote Lee - 'NICE!'

With the drilling jig - could you check / remark the holes using the mandrel you drilled for the rings? The holes in the rings seem to line up pretty well with Tom's plates - to my eye at least.

(https://lh3.googleusercontent.com/-4YWNChYG3-A/VqAoJDHlukI/AAAAAAAAAp4/-syW7Z61sZo/s800-Ic42/DSCF2560.JPG)
Title: Re: The Jigmaster Project
Post by: Rothmar2 on January 21, 2016, 09:54:29 AM
Thanks for checking that out Mike. Bit of a different deal with the drilling mandrels for rings and the frame, namely the hole diameters (ie. 3.0mm for the rings, 2.6mm for the frame to tap the 5-40 threads). But having said that, when I get my hands on Tom's plates , I will be able able to do better check. It's possible that the ring mandrel could be spot on, and I could use it to mark the centers for a new frame drill jig if it comes to that. I want to be 100% sure before I go ahead and drill any more frames, that they are accurate enough so there is no unnecessary wear on our sets of Tom's plates from misaligned holes. I have wondered that during the machining process whether the frame "sprung" out a bit from residual bending stress, and the now thinner section thickness? When I get back in phone range, I'll be able to get some more pix up to show what I mean.
  Have made up some spacers for the frame punch, and am ready to bend a couple of 501 width frames. One if these will (eventually) make its way to you Mike. Massive thanks for all you have done behind the scenes for me.
   Am really very uncertain whether I am going to be able to get the reel seats done without the use of a mill. Have been researching a couple of options, but going off what I'm reading, it's not looking good for the tools I currently have available. I really need to get my hands on a 6mm end mill to mount on the drill press, as a minimum at this point. The frame side of things might be stalled again for a while yet.
   But plenty of other things to do in the meantime...... ;)
Title: Re: The Jigmaster Project
Post by: Rothmar2 on January 30, 2016, 11:00:41 AM
Have given up with the mobile phone redirecting problems with photobucket, and tried a PC instead. Don't like doing it this way, but it will do for now.

Bit of an update, not a great deal of progress, but a bit more for those interested.

I salvaged this 316 hydraulic connection block that was in a scrap bin a while back, I figured I could make a reel seat from it

(http://alantani.com/gallery/21/10783_29_08_17_4_35_09_21702151.jpeg)

I had to make a faceplate up which could be used to bore the frame recess. It was quicker than having to mount the lathe's full sized faceplate, heavy and a PITA to take on and off repeatedly. The one shown was made from a blank flange, and a discarded 30mm diameter bolt, also salvaged from scrap. Thus I was able to use this setup in the 3 jaw chuck to machine the recess

(http://alantani.com/gallery/21/10783_29_08_17_4_46_40_217541561.jpeg)

Final check with the frame before removing from the lathe

(http://alantani.com/gallery/21/10783_29_08_17_4_45_50_217491303.jpeg)

Pretty happy with the result

(http://alantani.com/gallery/21/10783_29_08_17_4_41_12_217201785.jpeg)

I will be able to reset the seat on the faceplate to skim the rod profile recess, and the reel feet. I will show that when its done.
My conundrum at the moment is how to join these two parts together. Part of me wants to TIG them together, but I'm worried the heat might warp the frame. The other option is to drill and tap four countersunk screws. But trying to keep this all aligned while drilling into the curved joining surfaces is going to be tricky. Its actually doing my head in a bit.






Title: Re: The Jigmaster Project
Post by: Alto Mare on January 30, 2016, 12:17:14 PM
And the flame keeps burning hot...love it!
Thank you for keeping it going!

Sal

Title: Re: The Jigmaster Project
Post by: mhc on January 30, 2016, 02:50:31 PM
Looking at the photos, if you invert the assembly and drill a central hole vertically through the centre of the stand and into the frame, where the interface is near horizontal, then tap the frame hole and use a screw to hold the stand in place while you drilled the holes through the stand into the curved interface? The matching curved surfaces should stop rotational movement between the parts.

For photos I use picasa 3 without problems - but on a PC, haven't tried it on an iphone

Mike
Title: Re: The Jigmaster Project
Post by: Rothmar2 on January 30, 2016, 11:31:35 PM
Mike what you have described was the way I was thinking of going about it. Guess I get a "drain hole" under the spool by going this way. For looks, it won't win any awards, but I think I'll just have to go with it.
Probably get onto it tonight. If successful, I'm pretty much home and hosed.....bar quite a bit of chain drilling and filing of the frame cutouts to reduce weight, and trimming of the excess metal above the side plate mount holes (several more hours work there)....oh, and then the polishing. Once the mating holes are done, will then go back and machine the seat to final shape, bit of clean up filing there......and more polishing.

But there is a light back there somewhere with this stage of the project. I wish I had a mill.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on February 04, 2016, 10:16:04 PM
So have gone ahead and done the seat/frame join as Mike has described.

Mark out the hole location on the back of the seat. M6 bolt to use as the clamp

(http://alantani.com/gallery/21/10783_29_08_17_4_33_44_216941925.jpeg)

Set the frame up on the drill press.
Note the shims under one end to level the frame

(http://alantani.com/gallery/21/10783_29_08_17_4_31_37_216851846.jpeg)

Drill 4mm for pilot hole

(http://alantani.com/gallery/21/10783_29_08_17_4_41_18_21722998.jpeg)

Then 6mm

(http://alantani.com/gallery/21/10783_29_08_17_4_40_54_217201990.jpeg)

Put the clamping M6 bolt through and tighten down

(http://alantani.com/gallery/21/10783_29_08_17_4_39_00_217182376.jpeg)

Then drill 4mm screw holes around the locating clamp hole. The counter sunk screws for the join are M5.

(http://alantani.com/gallery/21/10783_29_08_17_4_31_19_2168285.jpeg)

Holes all drilled

(http://alantani.com/gallery/21/10783_29_08_17_4_46_17_21752455.jpeg)

Then run the M5 tap all the way through all four holes from the flat side while the frame/seat is clamped. This will makes sure the threads are straight between the two pieces.
The threads in the seat holes will come in handy for the next step for machining the feet.
 I then countersunk the holes so the screws will sit below the level of the seat.
At this time, still machining the feet, will show that in a separate post when completed.
 

Title: Re: The Jigmaster Project
Post by: David Hall on February 04, 2016, 11:47:55 PM
This is going to be the indestructible reel, drop it from aircraft, run over it with a tractor, I don't think anything will damage it, 
We need an appropriate call sign for this beast!
It's not a tank it's a ???????????????
Title: Re: The Jigmaster Project
Post by: Rothmar2 on February 05, 2016, 01:23:52 AM
Quote from: David Hall on February 04, 2016, 11:47:55 PM
This is going to be the indestructible reel, drop it from aircraft, run over it with a tractor, I don't think anything will damage it,  
We need an appropriate call sign for this beast!
It's not a tank it's a ???????????????


TIME VACUUM (tongue in cheek, but an element of truth there)
Title: Re: The Jigmaster Project
Post by: Robert Janssen on February 05, 2016, 05:20:07 AM
Well done. Definitely the right method. Welding that would have likely brought tears.
Making stands and feet is trickier than it looks.

PS: you might want to put a witness mark on that before you forget

.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on February 05, 2016, 07:37:22 AM
Thanks Robert, coming from you, that is great reassurance. I just felt any heat would distort the frame, and I'd be back to square one.
I'm sure you can picture what is coming next, another 2-3hrs tool-making to be able to finish the seat off.
But I'll be making a few 501 frames, so the time spent now will be worth it in the long run.
Title: Re: The Jigmaster Project
Post by: mhc on February 06, 2016, 01:54:46 PM

TIME VACUUM (tongue in cheek, but an element of truth there)
[/quote]

An element of truth indeed! Each 'episode' of this project has been a summary of many, many hours of work (and skill), not to mention the countless hours pondering materials, design alternatives and process options. Add a few lengthy interruptions / delays from circumstances out of your control, I think you are justified in calling it a 'Time Vacuum'. On the up side, you are on the downhill run with the first frame, and now have most of the tooling made, process in place and design sorted (more or less) for any subsequent frames you can talk yourself into making. There is a light at the end of the tunnel and I don't think it's a train coming!!

Having said that, I don't think 'Time Vacuum' will catch on, it needs to signify what has gone into making it, strength, tenacity, perseverance as well as what it is strong, stable, resistant - I'm thinking 'The Rock' but that is probably due to my geotech background.  ;D ;D

I think I am in breach of rule #18 - I had better go.   
Title: Re: The Jigmaster Project
Post by: Ron Jones on February 06, 2016, 08:24:09 PM
Truly impressive.
I believe the answer is yes, but are you keeping all of the jigs / plates your making up for this project? It would certainly help reduce the time of future reels.
Thank you for including us on your journey.
Ron
Title: Re: The Jigmaster Project
Post by: sdlehr on February 06, 2016, 08:49:31 PM
Add me to the list of folks along for the ride, enjoying the scenery. Well done!

Sid
Title: Re: The Jigmaster Project
Post by: Rothmar2 on February 06, 2016, 09:06:01 PM
Yes Ron, I most definately am keeping the tooling I have made. At a guess, I reckon I have 30-40hrs in just the frame alone, and a third to half that time is in making the tooling. My next challenge is trying not to lose any of it. I work on a ship, doing 5 weeks on, 5 off, and have a days travel to get to/from. Trying to keep it all together without someone on the other swing throwing it out makes me lose sleep...I will show you a photo of the tools I have made at some point, so you can get a better picture of what this has taken. I'd say there's 30-40lb of metal in just the tools!
I have shown a pic of the 501 frames bending stage, will be getting another bent today. I am hoping these will be much quicker to make, not being as wide, means much less surface to machine, and tools already done. I may still have an issue with the drilling jig for the end plate hole pattern, but I have a set of Tom's plates coming, and I will check that out more closely before I go ahead and drill any more frames. So I may still have some tooling work to do in future.
I have now all but finished machining the first reel seat, there will be a post with that as soon as I get back into phone range. So now it's down to "trimming the fat" off the frame. Not having access to a mill means chain drilling and a fair few hours of filing ahead. I don't think the polishing is going to be a quick process either.....
 I had a thought it would be nice to be able to pass the tooling I have made onto someone who might be interested in having a go at this themselves, but I think it would be too cost prohibitive in today's world of ridiculous freight charges. And it would take me a year of travel to get the tooling home bit by bit in my suitcase!
At this point I'm thinking I will probably only make 5-6 frames.
Title: Re: The Jigmaster Project
Post by: Ron Jones on February 06, 2016, 10:01:31 PM
Just a thought, but how about contracting out the final milling on land? If the goal is to make it all yours then I understand this isn't acceptable, but chain drilling and cleaning up is hours upon hours of work.
Ron
Title: Re: The Jigmaster Project
Post by: Rothmar2 on February 06, 2016, 10:31:50 PM
The reason why is cost. I can't justify paying around $40/hr for someone else to do this, when I can do it myself. I don't know what it's like in the US, but skilled tradesman cost an arm and a leg in Australia. I have a hard enough time putting money aside just to buy raw materials (SS plate etc), and I'm fortunate enough that I have access to the equipment I do at work. Otherwise there is no way I'd even consider something like this. I have a wife, kids, mortgage and plenty of bills to pay like everyone else, I can't afford for my hobbies to be any more expensive than they need to be.
Chain-drilling and filing is not that bad anyway. Yes it's time consuming, but time is something I have bit of out here. Beats sitting around watching movies like most other blokes do in their downtime. It just doesn't work for me, I'd rather do something productive....besides I can put the iPod in my earmuffs and groove away while I do this.
Title: Re: The Jigmaster Project
Post by: Ron Jones on February 07, 2016, 12:28:34 AM
As a submariner, believe me I can relate. If that is your deal brother then stick with it, it's working.
Ron
Title: Re: The Jigmaster Project
Post by: Rothmar2 on February 10, 2016, 12:24:47 AM
No problem Ron. A submariner! Yikes, I think some of what I do in the Offshore is risky enough, but underwater?! And the military! Tip of the hat to all those who serve their countries.

To machine the reel feet, it was yet another tool made to bolt to the faceplate. The curved face with the bolt holes was a piece cut from some scrap pipe that was very close to the diameter of the frame. In the second photo you can see a partial channel cut. I initially tried to take a bit of a shortcut by mounting the piece to the faceplate with the clamping kit I have used at other stages in this project. The problem was the overhang of the small boring bar from the tool post, there was too much deflection and chatter with the intermediate cuts. This necessitated the construction of the holding tool, and thus also having to machine the rod profile in two steps. I'll also add that I was able to maintain a chuck speed of 270rpm without out of balance wobble. Sufficient for this step, and also due to the sturdiness of this machine. If ever attempting this on a smaller lathe, a counterweight would need to be bolted to the faceplate.

(http://alantani.com/gallery/21/10783_29_08_17_4_44_54_21743357.jpeg)

The seat bolted to the holding tool with the cap head bolts

(http://alantani.com/gallery/21/10783_29_08_17_4_44_51_217422399.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_4_15_30_21625943.jpeg)

Check with a try-square, not quite there....

(http://alantani.com/gallery/21/10783_29_08_17_4_24_29_21655697.jpeg)

So slack off the holding tool from the faceplate, and slip a shim in under the tool and adjust until square, you can just see it in this pic

(http://alantani.com/gallery/21/10783_29_08_17_4_38_39_217162230.jpeg)

Once happy,  mount the faceplate to the lathe, can do a partial check with the dial gauge for squareness of the faceplate, I managed to get it under 0.1mm...good enough. Do a rotational  check by hand with the machine out of gear, before commencing machining, vital safety step...

(http://alantani.com/gallery/21/10783_29_08_17_4_46_08_21751965.jpeg)

Bore cut to roughly the middle of the seat, virtually no tool deflection or chatter this time around

(http://alantani.com/gallery/21/10783_29_08_17_4_38_12_21713563.jpeg)

Reverse seat on the holding tool, do some checks for squareness etc with measuring tools and light cuts to get everything aligned before cutting to final profile

(http://alantani.com/gallery/21/10783_29_08_17_4_43_31_217362425.jpeg)

Then change boring tool for facing tool and carve out the taper at the top of the footing

(http://alantani.com/gallery/21/10783_29_08_17_4_14_44_216212066.jpeg)

This took a while as I didn't bother to cut away the excess metal enclosing the bolt hole of the original piece. You can still see a remnant of this

(http://alantani.com/gallery/21/10783_29_08_17_4_34_47_217001806.jpeg)

When I removed the seat to reverse it for doing the other end, I used a grinder to remove the bulk of the metal. Note I have rounded off the sharp corners as well

(http://alantani.com/gallery/21/10783_29_08_17_4_43_04_21733879.jpeg)

Re-attach to the holding tool

(http://alantani.com/gallery/21/10783_29_08_17_2_32_28_216012488.jpeg)

And machine the other end. I used a 5degree taper, but at this point I'll have to re-mount the seat again, as the feet are far too long, and I want to increase the taper. I plan on filing the width back of the feet as well.

(http://alantani.com/gallery/21/10783_29_08_17_4_14_44_216212066.jpeg)

And now a sneak peek.....

(http://alantani.com/gallery/21/10783_29_08_17_4_42_28_217292500.jpeg)

And as Robert wisely suggested, a witness mark as well

(http://alantani.com/gallery/21/10783_29_08_17_4_11_26_21605128.jpeg)

Will get chain drilling and filing up ASAP.
Title: Re: The Jigmaster Project
Post by: steelhead_killer on February 10, 2016, 12:59:17 AM
Dude I hope you work for NASA!  That is some awesome work! 
Title: Re: The Jigmaster Project
Post by: broadway on February 10, 2016, 04:19:19 AM
Seriously, You amaze me! Every step is so well thought out, carried out and documented.
Awesome job, bro!
Dom
Title: Re: The Jigmaster Project
Post by: mhc on February 10, 2016, 12:26:51 PM
You are certainly opening my eyes to what can be achieved with a face plate and appropriate tooling - I can stop guessing how you were going to make the foot.
I've heard it's good practice to replace those 316 hydraulic connection blocks regularly, before they leak, or have you found enough already?  ::)

Mike
Title: Re: The Jigmaster Project
Post by: Shark Hunter on February 10, 2016, 01:33:49 PM
You have some serious skills Chris.
It just amazes me you can turn those giant pieces of metal into a fine work of art.
Thank You for taking us along. ;)
Title: Re: The Jigmaster Project
Post by: sdlehr on February 10, 2016, 03:12:01 PM
This entire thread is one amazement after another. Keep it up, I'm paying close attention!

Sid
Title: Re: The Jigmaster Project
Post by: Alto Mare on February 10, 2016, 03:33:04 PM
I'm amazed with every step you take on this project Chris. If there was such a thing, I vote this one thread of the year.

I'm going to take a little credit here, I pinned it and you could see why, but this has gone way past what I visualized it would go.

Excellent job!

Sal
Title: Re: The Jigmaster Project
Post by: Penn Chronology on February 11, 2016, 02:53:48 AM
I believe we should create a Alan Tani Hall of Fame award.

Guess who I feel deserves the first trophy? ;D
Title: Re: The Jigmaster Project
Post by: Cortez_Conversions on February 11, 2016, 03:25:17 AM
You're doing an awesome job Chris!
Title: Re: The Jigmaster Project
Post by: Rothmar2 on February 11, 2016, 05:02:50 AM
Quote from: Penn Chronology on February 11, 2016, 02:53:48 AM
I believe we should create a Alan Tani Hall of Fame award.

Guess who I feel deserves the first trophy? ;D

Robert Janssen for his Ambassaduer 3.0 thread
All the guys who have their own boards that are producing parts for members here
Alan Chui and his "source"
Sal
Daron
George
Gman
Irish Jigger
Mike (mhc)
Plus many others here who post their builds.

I be at the bottom of a very long list.

Actually have the frame roughly filed now to a usable shape, albeit very rough. Still much to do.
This frame is far from perfect, there are a number of "issues" with it. But, I assembled the reel last night without the bridge, gears, clutch and am relieved the spool spins like a dream.
The biggest niggle for me despite a few little slip-ups is WEIGHT. Going to have to do some very tedious extra work to try and machine a bit more off. I will get some more pix up next week.
But for now, this project will be shelved for a while. It has been a great learning experience for me, and will be looking forward to getting into the 501 frames in the future. I think the SS frame for the 501 will be a much better strength/weight gain mix than doing a 500 SS frame. There are a number of things I wish I had've done differently on this part of the project, but I hope I have shown its possible to build SS frames from plate/flatbar, rather than from pipe/round bar stock (too expensive).
Title: Re: The Jigmaster Project
Post by: Rothmar2 on February 14, 2016, 09:54:11 PM
Thanks again for your interest and kind words everyone.

To do the chain drilling, it all has to measured out and centre-punched beforehand. Each centre punch should allow a little bit of overlap. I used a 9mm drill in the cut-out corners, a 4.5mm drill for the other holes, and the centre punch holes are 8mm apart. Note I have "heavy" and "light" centre punches, the heavies for drilling, the light ones are the frame shape profile, helps me to keep track of everything

(http://alantani.com/gallery/21/10783_29_08_17_4_31_25_21684981.jpeg)

After drilling, it all looks a bit messy. I did have a few holes that wandered a bit.

(http://alantani.com/gallery/21/10783_29_08_17_4_34_01_216951422.jpeg)

Any metal left joining the cut-out piece to the rest of the frame was hit with needle files, and I used a sharp chisel to help break up any remaining strands, and to knock the waste piece out

(http://alantani.com/gallery/21/10783_29_08_17_4_26_09_216621602.jpeg)

I then used a die grinder with a straight shank carbide bit to grind away the dags, it makes pretty short work of it. I wore thick chemical rubber gloves and a face-shield, as thousands of tiny little needle shards are made during this process. Still ended up with the odd splinter.
Once most of the dags are removed, it's onto the files

(http://alantani.com/gallery/21/10783_29_08_17_4_43_12_217342187.jpeg)

Here I have used an angle grinder with a 1mm cutting disk to cut a groove to mark where I will cut back the frame edges, and chain drilled across the top of one of the cross bars of the frame

(http://alantani.com/gallery/21/10783_29_08_17_4_29_43_216751055.jpeg)

I completed the cuts using a hacksaw

(http://alantani.com/gallery/21/10783_29_08_17_4_35_59_21707908.jpeg)

One edge cut away...

(http://alantani.com/gallery/21/10783_29_08_17_4_41_29_217231793.jpeg)

Then more grinding and filing....frame taking shape

(http://alantani.com/gallery/21/10783_29_08_17_4_45_27_217471209.jpeg)

Early test fit, spool spins beautifully

(http://alantani.com/gallery/21/10783_29_08_17_4_12_49_216101864.jpeg)

And after about 5-6hrs of chain drilling, die grinding, drilling and tapping the rod clamp bolt  holes, and widening out the centre location hole that was used to locate the reel seat to frame, I am at this point....

(http://alantani.com/gallery/21/10783_29_08_17_4_33_04_21691657.jpeg)

Heading home from work over the next couple of days. So I probably won't get much done over the next few weeks. I may make some of the smaller parts while home, depends how many reels I get in for service.

And besides, I'm looking forward to further sessions with the Tank, hopefully with a sword on the end of the line.


Title: Re: The Jigmaster Project
Post by: steelhead_killer on February 14, 2016, 10:28:39 PM
incredible...
Title: Re: The Jigmaster Project
Post by: Ron Jones on February 14, 2016, 11:26:58 PM
And they say Craftsmanship is dead! Truly impressive my friend, can't wait for the next chapter.
Ron
Title: Re: The Jigmaster Project
Post by: broadway on February 15, 2016, 01:54:23 AM
What can I say this time? ... You amaze me!
Thanks for taking us through the process with you
Dom
Title: Re: The Jigmaster Project
Post by: Marcq on February 15, 2016, 02:29:57 AM
I say WOW  :o

Marc..
Title: Re: The Jigmaster Project
Post by: Tiddlerbasher on February 15, 2016, 09:39:35 AM
Thank you for the journey Chris - I'm luving this :)
Title: Re: The Jigmaster Project
Post by: mhc on February 15, 2016, 12:52:04 PM
You've made a lot of progress this stint - the frame is looking great.
Have a good break - and while you catching swords on the Tank, the rest of us will have time to think of more words to describe your work.
Title: Re: The Jigmaster Project
Post by: Mattman NZ on February 15, 2016, 11:59:48 PM
Man im impressed - you really need a mill . ;D
Title: Re: The Jigmaster Project
Post by: Yogi_fish808 on February 16, 2016, 12:19:01 PM
What an incredible level of craftsmanship on that frame! Hats off to you man, master yoda level. Somehow, I'd wanna see this masterpiece mated up with Sal's stainless sideplates and every other possible ss part available. That would really be the ultimate evolution of a jigmaster.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on February 16, 2016, 12:37:51 PM
Cheers for all the compliments guys, I really hope that this thread inspires and can give some guidance to someone out there to have a go themselves. Yes, this frame has taken a lot of time and effort, and even though it's not finished, the sense of satisfaction I have gained from attempting this has outweighed the challenges and difficulties I've had to overcome. Yeah a Mill would be fantastic, but unfortunately the man who offered to assist me with this project (who had a mill) passed away two days ago. I've come far enough using hand and hand-held power tools that I will finish this frame this way. But I will be looking into maybe contracting the milling work for the 501 frames to come. Mike (mhc) has gone above and beyond behind the scenes on this project for me, and I owe it to his generosity to produce a couple of shmick frames for his kindness. I'll get there Mike, it's just gonna take time.
I can't recommend taking on a project of kind enough for all of us who have this reel obsession. It really does open up a whole new skill set that you can apply to your reel work.
  Once again, thanks for the words of encouragement, and thank you for your interest.
Title: Re: The Jigmaster Project
Post by: Maxed Out on February 17, 2016, 06:44:26 AM
Very sorry to hear about your good friend passing. May he rest in peace


Thanks for sharing all your amazing wizardry and imagination and talent.

  Ted
Title: Re: The Jigmaster Project
Post by: mhc on February 19, 2016, 12:10:55 PM
Sorry to hear about your mate passing. I know you had a lot of respect for him and what he had achieved - from being involved in the design and construction of rock tunneling machines for hydro-electric schemes during his professional career, to building timber boats for personal satisfaction - and fly fishing. 
Title: Re: The Jigmaster Project
Post by: Rothmar2 on February 19, 2016, 07:41:12 PM
Thanks Ted and Mike. Yes, everyone who switches on a light down here owes him a debt of gratitude. Even up until a few years ago, he was still getting flown around the world to consult on tunneling projects. The few days I had with him fly-fishing out of his beautiful timber boat weren't enough. A great man, and true gentleman in every sense of the word.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on March 14, 2016, 07:54:45 AM
Getting close to the polishing stage of the frame. I have been able to fit in a bit of time while home to refine the cut-outs with some filing, just an hour here and there.

(http://alantani.com/gallery/21/10783_29_08_17_2_29_23_215901788.jpeg)

Also narrowed and shortened the seat feet (poet and didn't know it).

(http://alantani.com/gallery/21/10783_29_08_17_4_42_48_21731710.jpeg)

Tools used have been rat-tail files, couple of sizes and cuts, flats, and 1/2 rounds. Then needle files to do the rounding off. A dremel with a sanding drum has also had a bit of a run as well. Still don't think I'll have this reel finished anytime soon.
 But am looking forward to having the frame finished soon.
Title: Re: The Jigmaster Project
Post by: Robert Janssen on March 14, 2016, 11:59:35 AM

Good stuff. Thumbs up & pat on back. Seriously.

That is good work, and done by hand it is of another realm entirely. I know it is; i too spent a lot of time with drills and files and eyeball measurements back in the old days. The fact that it might turn out a little lopsided or not-quite-perfect just adds value to me.

Title: Re: The Jigmaster Project
Post by: Alto Mare on March 14, 2016, 12:31:49 PM
Quote from: Robert Janssen on March 14, 2016, 11:59:35 AM

Good stuff. Thumbs up & pat on back. Seriously.

That is good work, and done by hand it is of another realm entirely. I know it is; i too spent a lot of time with drills and files and eyeball measurements back in the old days. The fact that it might turn out a little lopsided or not-quite-perfect just adds value to me.



I agree with Doc.
Having a little imperfection reveals that it was built by a master and not a robot ;).
You have something very valuable there my friend and it should never go up for sale.
Sal 
Title: Re: The Jigmaster Project
Post by: STRIPER LOU on March 14, 2016, 12:34:48 PM
Awesome work Rothmar! Nothing like a mechanic with great hands. Wish you lived close by. We would have a blast together in the shop!
Regards,  ..  Lou
Title: Re: The Jigmaster Project
Post by: mhc on March 14, 2016, 12:54:54 PM
I'll go out on a limb and say that you have hand crafted the strongest jigmaster frame in the known world!
Mike
Title: Re: The Jigmaster Project
Post by: Penn Chronology on March 14, 2016, 03:10:39 PM
QuoteI'll go out on a limb and say that you have hand crafted the strongest jigmaster frame in the known world!
Mike

You are not out on a limb, you are the tree!..............!

As I look at the progress of this project, the word that keeps bouncing around in my head is WOW! This is a true labor of love. Think down the road about 100 years, some tackle guy is at a garage sale and see this old dusty reel in a bucket, buys it for $12.95. When he cleans it up, he see it is heavy and extremely engineered, so he takes some pictures, goes to his computer and writes a post on some future tackle collectors website. The post turns into a 30 page discussion until one of the members finds this old thread, lost in cyberspace for many years. Now fully documented, the reel go up for auction and some future collector is able to send his children to college from the sale of this masterpiece. What better legacy could a mechanic want?
Title: Re: The Jigmaster Project
Post by: Shark Hunter on March 15, 2016, 09:29:50 AM
I think the Key word there Mike is Masterpiece! ;)
Title: Re: The Jigmaster Project
Post by: Tiddlerbasher on March 15, 2016, 10:01:26 AM
Wow - such a talent :o
Title: Re: The Jigmaster Project
Post by: Rothmar2 on March 15, 2016, 11:29:48 AM
Thanks again for all the positive comments. Don't know of this frame is "The Masterpiece" yet. I hope after I do a couple of narrow frames I might have mastered things a bit better.
Mike, I have wondered during the hours of work  where this reel would finish up in the distant future. Certainly would be nice to be looking down and seeing your scenario play out.

I had a bit of a play with the polishing for a couple of hours today.

(http://alantani.com/gallery/21/10783_29_08_17_4_38_25_217141535.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_4_31_22_216831939.jpeg)

I used these as an experiment for removing some scratches and smoothing off

(http://alantani.com/gallery/21/10783_29_08_17_4_36_23_217091779.jpeg)

I just glued some 200 grit wet/dry to a worn out sanding drum, with Selleys Quik Grip. I had a couple pre-prepared. I keep them lubed with WD 40 while using them. The grit will wear down, but it's not too much of a big deal to glue another strip onto the   Sleeve if need be. Keep them wet, and they will last a reasonable amount of time.
  I then hit surfaces with the mini felt polishing discs for the Dremel. Used  Bordo polishing compound to bring out the shine.
Actually getting excited the frame is almost done.
Title: Re: The Jigmaster Project
Post by: Penn Chronology on March 15, 2016, 03:58:43 PM
[quoteMike, I have wondered during the hours of work  where this reel would finish up in the distant future. Certainly would be nice to be looking down and seeing your scenario play out.
][/quote]

There is no doubt that you are creating a piece of work that will go down in history. If you spent the rest of your life creating and selling these works, the best you could ever expect your market category to be would be true "Limited Editions". Every special interest has a high end, I believe you have raised the bar for fishing reels.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on April 18, 2016, 08:19:51 AM
Mike, once again thank you for your positive words. I'm not sure about me personally, raising the bar for fishing reels. There are a lot of people who have come before me, and many others still doing it,who deserve that accolade.  My motivation for all this largely came from seeing the SS plates Alan Chui had made for Sal. There was a bit of banter about "just need a SS frame now to get an all SS jigmaster". It got me thinking, "Could a frame be made?" Yes it can. Would I want to fish with an all SS Jiggy? No, probably not. Too heavy IMO, unless someone more skilled than this hack, could get the overall SS scantlings reducd to the point where the reel could be "practically fishable". To develop this is an entirely different realm from what I am capable of. That would truly be the ultimate "high end" for this design of reel.
  Anyway,  a little more to add to this after that ramble. While I have been at work this last few weeks, I haven't had the time or energy to put into this project until just the last week or so.
 I have done the ratchet, remade the shifter to make it a bit easier to get some purchase on. The stainless part is about 3mm higher than stock, and if you look close, there is a 1.5mm thick Black Delrin washer under it. This gives enough height to make it easier to get a decent push against, even with the extra ring for the left plate.

(http://alantani.com/gallery/21/10783_29_08_17_4_43_26_217351451.jpeg)

And the E-clip on the other end, with handmade pawl. Still a bit more fine tuning to do here, the ratchet is a bit stiff for my liking.

(http://alantani.com/gallery/21/10783_29_08_17_4_35_37_217041748.jpeg)

It may come as a surprise to those of you who have followed this, but I won't be doing any drag upgrades to this reel. I have decided to set this reel up for trolling with light line. The drag will be kept stock. With the weight of the frame, it's not going to be a reel to handle all day jigging/casting etc.  The stock steel main  gear will remain as well.
 I have however followed Irish Jiggers Jigmaster double dogging thread and added the extra dog, set for alternating.

http://alantani.com/index.php?topic=5966.0

The extra one currently is made from some work hardened brass (Piston shim plate from the ship's main engines, done 40,000hrs). I found some 2mm thick stainless sheet in some scrap today, will remake the dogs in stainless soon. I have the SS sleeve already. I have also cut the delrin U/G washer (left), original fibre on the right.

(http://alantani.com/gallery/21/10783_04_09_17_3_52_18_21802596.jpeg)

Now to the biggest gripe with this frame (aside from weight). The next photo is looking at the front cross-bar holes (facing the rod guides) with the lock and right side rings in place. You can see what I mean about not aligned. The top hole, not that big a deal, but the lower of the two is a problem, thinking I may have to leave this screw out altogether.

(http://alantani.com/gallery/21/10783_29_08_17_4_35_24_21703205.jpeg)

So I'm going to have to redo the frame drilling jig. Rather than go all out and make another, I have simply peened in some 2.5mm welding rod into the original holes to block them up. I will skim the faces of the jig true again, and will carefully use a set of Tom's Cortez plates as my template to re-punch the centres, and then re-drill the jig's holes, and re-check before proceeding with the 501 width frames.

(http://alantani.com/gallery/21/10783_29_08_17_4_23_51_21652300.jpeg)

I won't get it done this trip, but I have a couple of ideas to trim some more weight from the frame. And next swing, I will get the crank and handle done. I'm hoping to get the clutch lever and the spacer sleeve made before going home in a week. SS of course!
Title: Re: The Jigmaster Project
Post by: Alto Mare on April 18, 2016, 10:41:30 AM
Chris, here is what I think.
You should quit your job and work here full time for us.
We could all chip in a little each to cover your time and material, what do you say? ;D

Sal
Title: Re: The Jigmaster Project
Post by: mhc on April 19, 2016, 11:46:06 AM
Good to see you got some time to do a bit of 'reel' work - the clicker shifter is a piece of art. Is the bridge chrome over brass or stainless? I haven't drilled a hole in one of those (yet).
Mike
Title: Re: The Jigmaster Project
Post by: Rothmar2 on April 19, 2016, 01:03:23 PM
Yes Mike, stock plated brass bridge, drills nice and easy. Going to put the BP stainless bridges and gears into the narrows. Looking forward to getting home and seeing Adam's stars as well. Also should have a Cobalt Tib 501 spool waiting for me from Randy. That's going with the Cortez plates. With a stainless frame, it should be brutal!
Title: Re: The Jigmaster Project
Post by: Penn Chronology on April 19, 2016, 05:50:43 PM
I believe you should be able to target Marlin with your Jigmaster. New world record in the making.............................. :D
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 01, 2016, 12:09:12 AM
Have got a bit more done this week. Weather has been ordinary, so have had some hours to spend on getting some fine tuning done.
The main focus has been to get ring/frame hole problem sorted.
  I filed out the lock ring and original trim ring together until I got both of the problem holes fully in view.

(http://alantani.com/gallery/21/10783_29_08_17_2_30_44_21593393.jpeg)

(http://alantani.com/gallery/21/10783_05_09_17_2_43_10_218031264.jpeg)

I then lined up the stainless trim ring, and was able see where I had to remove metal from this new ring's holes

(http://alantani.com/gallery/21/10783_29_08_17_4_35_24_21703205.jpeg)

Once that was done and test fitted with the stock screws, it was time to machine down some 5-40, 3/8 SS  countersunk screws to suit. I did a bit of a thread on this....

http://alantani.com/index.php?PHPSESSID=h5k2ih50prov0h91lljeamafk7&topic=16302.0

The screw for the badly misaligned hole needed a lot of material removed to be able to get it in. There is still the slightest bit of bevel to tighten onto the lock ring. It looks unsightly, but I just have to go with it.

(http://alantani.com/gallery/21/10783_05_09_17_3_05_50_218041880.jpeg)

Eventually got all 6 lock ring screws in

(http://alantani.com/gallery/21/10783_29_08_17_4_45_39_21748823.jpeg)

I also drilled the extra left end ring to get rid of a bit of weight. Would really like to get this milled some day, but this will do for now.

(http://alantani.com/gallery/21/10783_29_08_17_4_11_04_21604445.jpeg)

I have a T-bar made, and a crank partly done. Should get it finished this week. Will show that when it's complete.
I adjusted the ratchet tension to where I was happy with it, just carefully bent the copper spring outwards. I don't feel excessive resistance while cranking the reel with the ratchet on now.
So I can feasibly take it fishing. Here's a sneak-peek what it will look like.

(http://alantani.com/gallery/21/10783_29_08_17_4_42_53_21732391.jpeg)

Still a lot of things to do though. The clutch lever, SS dogs, handle/crank, rod clamp, new spool arbour (Thanks Mike!) and I still want to do a bit more skimming of the frame/reel seat next time away. Have the SS sleeve, and jack/yoke to drop in when I do the final grease up assembly. I have also made a SS spacer sleeve for the drag.

But at least it's "fish able".
Title: Re: The Jigmaster Project
Post by: mhc on May 01, 2016, 08:31:05 AM
Thanks for the preview, it's good to see it with the rings on. I'll bet you're looking forward to fishing it after all the work you have put into this project.
Mike
Title: Re: The Jigmaster Project
Post by: Shark Hunter on May 04, 2016, 05:44:55 AM
Truly an amazing piece you have there Chris. Good Job my Man! ;)
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 04, 2016, 06:42:09 AM
Thanks Daron. It's not going to be a shelfy either. I'm actually pumped to take it fishing.
I'm just loving to custom work that has been put up on the forum lately by so many other members.
Lou and his acrylic masterpieces.
Marq's carbon fibre work.
Mattman's spool mods.
Ted's continual mix and matching, and tweaking.
And hats off to anyone I've missed.
Keep it coming!
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 11, 2016, 09:21:48 AM
A little more done in the last week.

Fitted the SS sleeve, coarse pitch.
The spacer to go in is self made.
Leaving the stock jack and yoke for the time being, but will replace with SS at a later stage. Mike also sent me an SS eccentric (Newell?) to go in with new jack/yoke.

(http://alantani.com/gallery/21/10783_29_08_17_4_26_14_216631055.jpeg)

UG delrin washer.

(http://alantani.com/gallery/21/10783_29_08_17_4_36_35_21710259.jpeg)

I got around to the clutch lever. It's 2mm SS sheet. The screw is SS M3, and the lever is tapped at the stopper end. The stopper is delrin, tapped M3.

(http://alantani.com/gallery/21/10783_05_09_17_5_01_06_218061541.jpeg)

A little blue loctite on the screw before fitting, and down the bore of the stopper.

(http://alantani.com/gallery/21/10783_05_09_17_5_06_33_2180875.jpeg)

Tighten it all together

(http://alantani.com/gallery/21/10783_05_09_17_5_01_42_218072254.jpeg)

And all ready to go

(http://alantani.com/gallery/21/10783_05_09_17_5_00_25_21805225.jpeg)

Here's a look at the crank/T-bar. Still unfinished at this point. I have a bit of length trimming to do to the handle. I'll need to get to my father-in-laws to do that, it's a too large a piece to do on my mini lathe. Using a 10-49 star at the moment, but looking forward to getting one of Adam's soon. The crank is going to have a " little something" extra fitted to it down the track. I'll show that when it's done in time.

(http://alantani.com/gallery/21/10783_29_08_17_4_41_34_217242313.jpeg)
Title: Re: The Jigmaster Project
Post by: mhc on May 13, 2016, 11:05:59 AM
I like your delrin stops on the eccentric levers, it would work well on Tom's plates to protect the anodized finish. I've been thinking of doing the same thing after seeing the lever you made for your 6/0 project - http://alantani.com/index.php?topic=10286.90 (http://alantani.com/index.php?topic=10286.90) The handle grip is looking good as well - the stainless inserts look great.

Mike
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 20, 2016, 09:52:47 PM
Got the T-Bar completed this week.
The sleeve was made in similar fashion to the 6/0 handle. Delrin bearing inside, with M5 cap head bolt shaft. The end of the crank is tapped M5, and the lock-nut has 3.5mm hole to tommy bar it tight. This also adjusts the axial float of the handle. The thread at the end of the sleeve to screw into the T-Bar is 3/8BSP. I filed a slight flat at this end to tighten the T-Bar to the sleeve.

(http://alantani.com/gallery/21/10783_29_08_17_4_35_50_21706521.jpeg)

And mounted onto the reel. Mike had sent me one of Adam's curved stars previously, shown here

(http://alantani.com/gallery/21/10783_29_08_17_4_26_29_21664406.jpeg)

But we had some straight arm ones coming, and they arrived yesterday.
I was waiting to see this one so I can plan the idea I have for the crank. This will be the one I'll go with for this reel.

(http://alantani.com/gallery/21/10783_29_08_17_4_35_42_217051746.jpeg)

The curved star will go on the Cortez Jigmaster I'll be assembling soon.
I might actually get a chance to fish this current reel this coming week. I'll be spooling it with 8kg test, and see if I can find a school size BFT for it.
Title: Re: The Jigmaster Project
Post by: David Hall on May 21, 2016, 07:49:47 AM
Okay next picture should be on the water fishing!
Can't wait.
Title: Re: The Jigmaster Project
Post by: Tiddlerbasher on May 21, 2016, 08:37:56 AM
Lovely work Chris :)
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 30, 2016, 10:50:57 PM
Sorry David, no pics of this one fishing....yet. It was with us in the tin-dish with the Tank, but due to sea conditions it didn't get used.


Here is a run down of what I have done so far to build the rod clamp.

This crude mould was made from a large plastic drill container, cut and taped at one end. It's 65 x 24mm.

(http://alantani.com/gallery/21/10783_29_08_17_4_31_48_21686557.jpeg)

Pre-cut fibreglass pieces to fit in the mould. The bottom 6 layers are 450g biax cloth, the rest of the layers will be 450g csm. My reasoning being for this layup, is that the biax will provide the tensile strength where the piece will be under  tension when the clamp nuts are tightened down. The csm will primarily act to build up the slab thickness for machining the clamp shape.

Mix the resin, in this case polyester. After the core piece has been shaped, epoxy and carbon fibre will be layed over this core. The epoxy will bond over this polyester core no problem

(http://alantani.com/gallery/21/10783_29_08_17_4_45_18_217462062.jpeg)

Pour a little resin into the mould and let it level out

(http://i1083.photobucket.com/albums/j393/westozwayward/Mobile%20Uploads/photo_zpszmrbejoh.jpg) (http://s1083.photobucket.com/user/westozwayward/media/Mobile%20Uploads/photo_zpszmrbejoh.jpg.html)

Take first piece of biax and lay into mould, push fibreglass into resin to drive out air

(http://alantani.com/gallery/21/10783_29_08_17_4_42_03_217261301.jpeg)

Continue adding a little resin, then the biax cloth. Once the 6 layers of biax are in, continue with the csm.

(http://alantani.com/gallery/21/10783_29_08_17_4_33_41_2169325.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_4_13_21_21613934.jpeg)

Keep adding layers until the desired thickness is reached. I was shooting for 18-20mm

(http://alantani.com/gallery/21/10783_29_08_17_4_29_37_216741250.jpeg)

Allow the resin to cure for 24 hours, then pull slab from mould.

(http://alantani.com/gallery/21/10783_29_08_17_4_42_13_217271581.jpeg)

The piece was then sanded on a flat surface to true up the faces so I could mount on my mini-lathe's faceplate.
Set up the boring bar and skim the rod profile. The aim is to not skim too far, so as  not to cut into the layers of biax.

(http://alantani.com/gallery/21/10783_29_08_17_4_25_56_216612386.jpeg)

This is as far I have got for now. I'll probably get a little done while at work, fab the nuts/bolts and get the holes drilled in the core piece. I will do the carbon fibre sheathing when I get home next.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on June 26, 2016, 10:00:24 PM
Not a great deal of progress on this reel lately. I have made the reel clamp screws and nuts, and drilled the fibreglass core to suit. The screws are M6 that go into the frame, and M4 at the nut end. Will hand cut and then file the drive slots into the nuts at a later stage. The drive end of the nuts sit neatly in a recess on the clamp.

(http://alantani.com/gallery/21/10783_29_08_17_3_38_32_215241974.jpeg)

 The reason I haven't done much to the 500 is this.....

(http://alantani.com/gallery/21/10783_29_08_17_3_38_18_215221281.jpeg)

Been busy on the first of the SS 501 frames. Although I have cheated a little this time around. Mike sent me a couple of Penn International 12T reel feet to see if they could be used.

(http://alantani.com/gallery/21/10783_29_08_17_3_37_51_215192358.jpeg)

But there was a slight difference with the radius of the 12T foot, just a shade too big...

(http://alantani.com/gallery/21/10783_29_08_17_3_37_55_215202363.jpeg)

But there was enough meat in order to re-bore/skim the radius of the SS frame into these stands. Of course, a tool had to be made to accomplish this

(http://alantani.com/gallery/21/10783_29_08_17_3_38_11_21519921.jpeg)

The faceplate was skimmed true on the lathe, and the frame diameter skimmed onto the faceplate for reference. The holding tool was then clamped to the faceplate and carefully aligned so the new frame radius could be machined into the seat. You can't see it in the photo of the tool, but there is a jacking bolt on the face of the angle bar that sits on the faceplate to assist with alignment. Tedious to set up, but once set correctly it didn't take long to machine in the new radius with the boring bar, even with light cuts.

(http://alantani.com/gallery/21/10783_29_08_17_3_38_25_215231796.jpeg)

The screws to hold it all together are M5, and I used the same method with the 500 frame to hold the seat and frame together while I drilled and tapped the screw holes. You can just see the clamping hole in the middle of all the screw holes.

When finished, one of these frames is going to Mike. He has been a big part of this project with me. There will be a few more Jiggy frames before I move onto other reels. Have a couple of extra twists to reveal in time with them as well.
I have about another week a work, so will be getting the frame cut-outs done before going home, where I will do final filing and polishing. Will show an assembled 501 then. This frame may get my set of Cortez plates mounted to it, but I have a franken-501 that will more than likely finish up this first narrow one. See how it all goes together when I get home.
Title: Re: The Jigmaster Project
Post by: mhc on June 27, 2016, 10:21:29 AM
Great work Chris (again) the narrow frames are looking good. I'm glad you could use the 12T stands with a bit of modification. BTW - I wouldn't consider it 'cheating' to make use of existing components - your frames are the centre piece of the project - and the rings of course, and the clickers, side plate lock screws, rod clamp kit, eccentric lever, handle and grip.

Mike
Title: Re: The Jigmaster Project
Post by: Alto Mare on June 28, 2016, 10:33:43 AM
At times when I think you might have ruined one of your parts, it always comes back looking amazing from you ironing it out.
As always, beautiful work!

Sal

Title: Re: The Jigmaster Project
Post by: David Hall on June 28, 2016, 10:03:47 PM
Always makes me smile and feel good when I see the things you come up with I can't help but think anything is possible.
  ;D ;D ;D ;D
Title: Re: The Jigmaster Project
Post by: Rothmar2 on June 28, 2016, 11:34:58 PM
Sal, I've had a few heart in mouth moments this past couple of weeks, and have just had another this morning....but it should be OK. I work on the principle "measure at least 3 times, attempt to cut once, and if for a moment something doesn't seem right, stop and re-assess....then start again". Truth be known, I've had a broken tap and a drill during the course of these two narrow frames. Both of which took a fair bit of careful work to remove and then rectify the scars. That's a good thing with using stainless for me, I can weld and re-fair it if need be. I had to do this once on one of these frames.
  This morning was drilling the cut-outs on the frame. The radius in the corner of cut-out comes dangerously close to the reel seat screw holes. I don't think I'll use the 12T seats again. Going to have to be extra careful around this area when doing the final shaping/fairing. I won't be able to get a pic up until next week to show what I mean.
Thanks again for your interest guys. Yep, anything is possible, just takes time, will and effort.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on July 03, 2016, 12:21:48 PM
I had noticed that since adding the SS gear sleeve that there was a little bit of radial slop while turning the handle.
It got me thinking about an arrangement to support the handle end of the sleeve.
  I had previously made a SS spacer, and felt it was a little too short by about 0.5mm, as there didn't seem to be any increase in drag over the first turn of the star, even with a coarse thread.
 So remove the bridge and gears and get some measurements.


First measure the depth of the opening. It's about 9mm deep, but the little grooves where this piece has been expanded with a press and die I'm guessing are about 2mm, so effective bearing surface is 7mm wide.

(http://alantani.com/gallery/21/10783_29_08_17_3_38_40_21525705.jpeg)

Measuring the width, 13.4mm

(http://alantani.com/gallery/21/10783_29_08_17_3_38_46_21526343.jpeg)

Here's the spacer sleeve, a shade under 12mm, the new piece will be 12.4mm when finished.

(http://alantani.com/gallery/21/10783_29_08_17_3_39_02_21527820.jpeg)

Now I had an off cut of 25mm black delrin, which I was going to use as the bearing surface. Drilled the bore out to 12mm.

(http://alantani.com/gallery/21/10783_29_08_17_3_39_46_215292254.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_3_39_50_215302392.jpeg)

Next rough out the new sleeve in an old 316 SS pump shaft. The shoulder is 13.2mm, and the stem is a shade over 12mm diameter

(http://alantani.com/gallery/21/10783_29_08_17_3_39_19_2152896.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_3_41_06_215382324.jpeg)

Centre drill the end, then bring up a 10mm drill to bore the spacer

(http://alantani.com/gallery/21/10783_29_08_17_3_40_19_215321020.jpeg)

Once drilled, I had to carefully clean up the bore with some coarse emery to widen it out a touch, to get the sleeve to fit through

(http://alantani.com/gallery/21/10783_29_08_17_3_40_28_215331927.jpeg)

Once happy, then push the delrin piece over the stem of the new spacer until it butts up against the 13.2mm shoulder.

(http://alantani.com/gallery/21/10783_29_08_17_3_40_40_215341343.jpeg)

Then start trimming the delrin back. Face off to the length of the sleeve. Then trim down the diameter.

(http://alantani.com/gallery/21/10783_29_08_17_3_40_44_215351034.jpeg)

Unfortunately, the delrin started to slip and pull off the sleeve.

(http://alantani.com/gallery/21/10783_29_08_17_3_40_53_21536591.jpeg)

So roughed up the stem with some coarse emery

(http://alantani.com/gallery/21/10783_29_08_17_3_41_01_215372432.jpeg)

Then skimmed a couple of very fine grooves with the tip of the lathe tool on the sleeve to provide some hold for the glue
Pushed the delrin back on with some of this to bond the pieces together. Waited a half hour or so to let it cure.

(http://alantani.com/gallery/21/10783_29_08_17_3_41_10_215391300.jpeg)

Was then able to skim the delrin sleeve down to 13.4mm, without further slippage. And check for a snug fit

(http://alantani.com/gallery/21/10783_29_08_17_3_41_23_215401731.jpeg)

Then trimmed 2mm off the length so the delrin would not get torn up by the grooves in side plate insert

(http://alantani.com/gallery/21/10783_29_08_17_3_41_30_2154110.jpeg)

Piece parted off and ready to be used.

(http://alantani.com/gallery/21/10783_29_08_17_3_41_34_215421571.jpeg)

Reassemble bridge to plate. Put the new sleeve in before tightening down the 4 bridge screws.

(http://alantani.com/gallery/21/10783_29_08_17_3_41_39_215431535.jpeg)

And all together.

(http://alantani.com/gallery/21/10783_29_08_17_3_41_45_215441924.jpeg)

Time will tell if the delrin will hold up, but for the time being, the slop has now gone from the crank. There is a barely perceptible rub to be felt at this point. I will put a thin smear of grease over this bearing at a later stage.

Title: Re: The Jigmaster Project
Post by: mo65 on July 03, 2016, 01:13:01 PM
Hey, that spacer is the whip! That radial slop drives me crazy. I'd love to have a handful of those.
Title: Re: The Jigmaster Project
Post by: Fishy247 on July 03, 2016, 05:13:45 PM
Just discovered this thread...great way to kill a couple of hours at work! Amazing stuff you're doing there. That jigmaster is truly a work of art! Do you know the weight of it yet?

Mike
Title: Re: The Jigmaster Project
Post by: mhc on July 04, 2016, 10:55:01 AM
I know you said you were setting this reel up for light trolling and intend to use a stock drag set up, but I'm thinking with the continuous improvements, including this latest brilliant addition of supporting the gear sleeve with a delrin encased stainless spacer, it wouldn't hurt to add a couple of drag washers - even to the existing steel gear. The reel still has the quick spool change feature - you could fish light line and drag as you said but have the option of changing to a spool of heavier braid if you change your mind.

Mike   
Title: Re: The Jigmaster Project
Post by: Rothmar2 on July 18, 2016, 09:37:01 PM
Have all but finished the first 501 frame. Just a bit more polishing to do, and then I'll be sending it off to Mike.
Thanks for all your patience and help with parts and tooling for this project mate, I really hope you like this frame. Make sure you post up a few pix with it assembled with some plates. Will probably be another week or so before I will get my 501 frame finished.
I'll then get back onto completing the 500.

(http://alantani.com/gallery/21/10783_29_08_17_3_42_00_21546480.jpeg)

Title: Re: The Jigmaster Project
Post by: mike1010 on July 18, 2016, 10:02:09 PM
Beautiful, Chris.  I hope someone from Penn is following and appreciating this.
Title: Re: The Jigmaster Project
Post by: Alto Mare on July 18, 2016, 10:09:50 PM
Chris, if you are not proud of that piece right there, there is something wrong with you.
This has been a nice ride, thank you! Also, thanks for being a member here and sharing your talent with us...amazing work!

You're right Mike, that piece belongs in the case at Penn.

Sal
Title: Re: The Jigmaster Project
Post by: Shark Hunter on July 18, 2016, 10:24:25 PM
Great work Chris. That is one well earned frame!
Title: Re: The Jigmaster Project
Post by: STRIPER LOU on July 18, 2016, 10:37:25 PM
Chris, absolutely brilliant work. Its been a pleasure to follow. Keep at it my man!
Regard's,  ..  Lou
Title: Re: The Jigmaster Project
Post by: Rothmar2 on July 19, 2016, 12:13:17 PM
Cheers guys. Yeah, pretty happy with this one Sal, and happier that it is going to Mike. He has procured a lot of the taps & dies, extra parts (Alan C's, Adam's, and some eBay stuff) that have gone into this project. Most of this had come from overseas, so the freight charges alone are scarey. I would also like to thank Tom Hryniuk, he has been a big help ensuring we get the correct taps/dies. Unified National standard is not very common here in Australia, particularly in the smaller diameters and high TPI sizes. Tom has assisted with getting in some of the tooling we have needed. Thank you Tom!
Lou, you commented about what a blast it would be to share a workshop, we'd be like two kids with their first box of matches! Would still like to be able to get my hands on some of that incredible stock you're making your pieces of art from.
Fishy247 (Mike) I went looking for the digi scales at home today to get a weight figure for the 500 for you. Haven't been able to find them....yet. But will get a figure for you at ASAP. I'll warn you now, the 500 is no lightweight! The 501 frames, while still adding a bit of weight, will be less noticeably so.
I have a couple more 501 frames bent. There will be a surprise down the track with at least one of those. It will come together next time at work. Credit in advance to Mike for the concept. Looking forward to making it happen!
Title: Re: The Jigmaster Project
Post by: thorhammer on July 19, 2016, 11:50:22 PM
Thanks for this amazing thread my man! That's just out of my mind how you conceptualize this stuff and then beast a piece of metal into realization.  I'd have as much success painting the Mona Lisa in the dark with a rattle can.

Thor
Title: Re: The Jigmaster Project
Post by: Marcq on July 20, 2016, 05:18:39 AM
Looks bad ####!!  8)

Marc..
Title: Re: The Jigmaster Project
Post by: Penn Chronology on July 20, 2016, 02:42:25 PM
It is good to know that a skilled man is willing to put this much time and heart into a fishing reel. Absolutely brilliant and unique work. Priceless!
Title: Re: The Jigmaster Project
Post by: mhc on July 29, 2016, 09:56:24 AM
The 501 frame arrived this week, thanks a million Chris! - it's every bit as nice as it looks in the photos;

(https://lh3.googleusercontent.com/-GAkoOMi7tGo/V5scmbCjkhI/AAAAAAAABAc/rEzokVR4ryoDeitMUTz3OsOiQfNffLTNgCCo/s800/DSCF2750.JPG)

I have mounted Penn side plates with a set of stainless rings made by Chris (see page 1 of this story), stainless internals by Alan C, handle arm and star by Adam, and a chrome 501 spool.

(https://lh3.googleusercontent.com/-LLsTD-vt2DM/V5sjVgVpS5I/AAAAAAAABAo/oauCmblFMn0g55FWxBEA6Q91uwvABP_-gCCo/s800/DSCF2753.JPG)

(https://lh3.googleusercontent.com/-oUlZ_ZEgWtE/V5skJruJtaI/AAAAAAAABAs/-Mk7AwDNKOA1RUo8NbFuwzlgINnsAlz3wCCo/s800/DSCF2755.JPG)

And together with it's stable-mate, a mostly stainless '99' width jigmaster.

(https://lh3.googleusercontent.com/-UCoXeZIU5eU/V5sk_JkmIQI/AAAAAAAABA4/Eecq23ruWVMaY3l1GcNc8ZFzFLwdDgsNgCCo/s800/DSCF2757.JPG)

Thanks again Chris - I would have posted these photos a few days earlier but I couldn't put the frame down long enough to assemble the reel.  :D

Mike

 

Title: Re: The Jigmaster Project
Post by: Rothmar2 on July 29, 2016, 09:34:38 PM
Thanks for posting those up Mike. My frame is done except for the polishing. As you know, I'm trying to fit my Cortez plates to it, but have some tweaking to do to get it together. Will get a post up when I have succeeded.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on August 17, 2016, 01:39:16 PM
After finishing the first of the 501 frames, I was curious to see if I had got the side plate holes accurate enough for some Cortez plates. They certainly looked close to lining up. Much more so than the 500 frame. A trial fit saw a little resistance on two of the screws. Rather than leave it this way, I modified the kit screws a little in an attempt to reduce the wear on plate holes. Please note, this is not a reflection on Tom's work, but the lack of precision on my part.
  What I did was file down the threaded part of the shank that was not engaging with the frame holes.
Mount the screw by the cap head end, and take a flat faced needle file to about 2/3 of the threaded shank, from the underside of the cap head. You want the end of the shank to be un-touched

(http://alantani.com/gallery/21/10783_29_08_17_3_42_25_21547172.jpeg)

Touch up the filed area with some fine emery when satisfied the edge of the thread is flattened off sufficiently

(http://alantani.com/gallery/21/10783_29_08_17_3_42_39_215482158.jpeg)

If you look closely, you can see the thread on the end is untouched.
Then using an old post bar, take the screw and wind it in at one end until it bottoms out.

(http://alantani.com/gallery/21/10783_29_08_17_3_42_53_215491928.jpeg)

Then mount the bar into the drill chuck, and using a coarser file, file off the little ridges on the cap head. Finish with the emery.

(http://alantani.com/gallery/21/10783_29_08_17_3_43_00_215502106.jpeg)

Remove screw from the post using the hex key, nice smooth head.

(http://alantani.com/gallery/21/10783_29_08_17_3_43_19_21551931.jpeg)

While we're at it, might as well hit it with a bit of polish from the little Dremel polishing wheels

(http://alantani.com/gallery/21/10783_29_08_17_3_43_36_215522297.jpeg)

Bring out the shine (not a great pic)

(http://alantani.com/gallery/21/10783_29_08_17_3_43_56_21553761.jpeg)

Each of these screws only take a few minutes  once set up.
Then mounted the plates to the frame.

(http://alantani.com/gallery/21/10783_29_08_17_3_44_10_215552364.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_3_45_14_21556533.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_3_44_01_21554314.jpeg)

The Tiburon spool was supplied by Randy, Vintage Offshore Tackle. I soaked the ball bearings from the Cortez kit for a couple of hours in TSI 321, then drained them off before fitting the spool. The free-spool time was amazing! Very happy!
Still need to make a few more parts before final assembly and prepping for fishing.
Will post that up later. Have BP drive train gear on standby.
But very pleased to have been able get the 501 frame to fit the plates.



Title: Re: The Jigmaster Project
Post by: Tiddlerbasher on August 17, 2016, 02:39:32 PM
WOW that is gorgeous :o
Title: Re: The Jigmaster Project
Post by: STRIPER LOU on August 17, 2016, 02:48:13 PM
Beautiful work as always Chris!!!!
...............Lou
Title: Re: The Jigmaster Project
Post by: Penn Chronology on August 17, 2016, 04:14:01 PM
AMAZING!!!!
Title: Re: The Jigmaster Project
Post by: broadway on August 17, 2016, 04:23:19 PM
Amazing job bro! It's a modern art masterpiece.
Hope you enjoy that reel... you certainly earned it!
Thanks for showing what can be done,
Dom
Title: Re: The Jigmaster Project
Post by: sdlehr on August 17, 2016, 04:41:09 PM
Incredible work, Chris! You didn't say if your screw modification improved the fit any... was it worth the effort?

Sid
Title: Re: The Jigmaster Project
Post by: basto on August 18, 2016, 04:04:55 AM
Very impressive! That`s dedication. You have taken custom to another level.
congratulations
Basto
Title: Re: The Jigmaster Project
Post by: mhc on August 18, 2016, 10:43:30 AM
Great work (again) - the plates and spool really go well with the frame.
Thanks for sharing your idea to file down the mounting screw threads where they contact the plates - it will help me with my rough stand & spacer experiments when the holes are not perfect and the screws can be a little hard to start.
Mike
Title: Re: The Jigmaster Project
Post by: Rothmar2 on August 18, 2016, 04:20:18 PM
Sid, yes it was worth the effort, although I have to hold the plate up off the frame face a little while setting the screws. There is the slightest hint of thread etched into the two holes that I was concerned about, but overall, it does not feel as tight as when I first attempted to fit the plates. I will just keep the site mantra of greasing these mounting holes when doing the full prep, and I think I'll be OK.
Mike you know as I've PM'd you, but didn't post previously, I had to shorten the screws a little as well. Removed about 1.5mm off the kit screws, with a belt sander......except for one you also know about!  ::)
Thanks for the kind words again guys.
Title: Re: The Jigmaster Project
Post by: thorhammer on August 19, 2016, 04:27:31 PM
Wow. just wow. Nice work, dude!
Title: Re: The Jigmaster Project
Post by: Rothmar2 on November 28, 2016, 01:06:26 AM
Update for those following.

I have had some drastic changes to my work situation over the last few months. Long story short, becoming a victim of the oil and gas down-turn, and so called "globalisation" (read scheme for the rich to get even richer). So I have had an extended time at home, and have been busy with alternative employment to try and keep afloat, so I haven't had much spare time. Thankfully, for the time being, I have returned to my usual job, and have been able to progress things a little.

I have started on building the finishing pieces for the 500, namely the reel clamp.
I acquired a piece of carbon fibre tape, and some clear epoxy. Inspired by Marcq's custom work, I am wrapping the fibreglass core to finish it off.

(http://alantani.com/gallery/21/10783_29_08_17_2_23_53_21562715.jpeg)

Mix epoxy and apply resin to the shaped core

(http://alantani.com/gallery/21/10783_29_08_17_2_24_03_215631813.jpeg)

Coat the whole piece evenly and allow to cure for a few hours until tacky

(http://alantani.com/gallery/21/10783_29_08_17_2_24_10_215641935.jpeg)

Once it has tacked, but not hardened, wrap the core with the carbon and press it into the resin (note gloves)

(http://alantani.com/gallery/21/10783_29_08_17_2_24_16_215651764.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_2_24_26_21562388.jpeg)

Cut along the edge line to wrap up the sides

(http://alantani.com/gallery/21/10783_29_08_17_2_24_31_215671918.jpeg)

Press sides in until held all the way around, and allow to cure. The side with the rod profile will be done after the external faces are complete.

(http://alantani.com/gallery/21/10783_29_08_17_2_24_42_215682382.jpeg)

Once the carbon layer has cured, apply a couple of sealing coats of resin and allow to cure hard, before sanding to fair the piece. This is where I'm at now, will show more in time as I progress.

(http://alantani.com/gallery/21/10783_29_08_17_2_24_47_21569929.jpeg)

While I didn't have a lot of free time while home, I did get a little done on the Cortez build. I shaped a crank and eccentric lever, to kind of tie in with Adam's curved star.
Still have a bit more polishing to do on the crank after I have made a handle, and have a couple of SS counterweights roughed out in readiness. Now if I can just get Striper Lou to part with a piece of his acrylic stock (dark blue/cobalt and white swirl) to match the spool, I'll be super stoked! In the meantime, I will knock something else up instead.

(http://alantani.com/gallery/21/10783_29_08_17_2_25_40_215731874.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_2_25_26_21572737.jpeg)

The drive train is in. I had the little knock from one of the dogs on the BP bridge against the cut out on the plates. A quick hit with a needle file off the corner pointed to, soon fixed that.

(http://alantani.com/gallery/21/10783_29_08_17_2_24_56_215701748.jpeg)

I also made myself a 5 stack, out of 0.5mm SS shim stock. The CF is 0.4mm. There is a 0.6mm Delrin UG and a 0.6mm on top of the drag stack, flat for now, but will make a delrin belleville later. I also had to machine up a sleeve spacer, the supplied one with the BP gears was a shade too thick.
A few of the stack parts below.

(http://alantani.com/gallery/21/10783_29_08_17_2_25_18_215711012.jpeg)

The only thing I'm a little disappointed by is free-spool is not great, only a couple of seconds. I have done a polish on the spool shaft and inside of the pinion, but no improvement. Might have to have a closer look at the jack springs perhaps?
Title: Re: The Jigmaster Project
Post by: twotone on November 28, 2016, 04:13:56 AM
Wholly molly.

Your work is brilliant.

Been following, Thx for posting!
Title: Re: The Jigmaster Project
Post by: mhc on November 30, 2016, 07:17:10 AM
Good to see you back on deck. Very neat work on the eccentric lever, is that out of 2mm thick stock?
Mike
Title: Re: The Jigmaster Project
Post by: Rothmar2 on November 30, 2016, 12:07:28 PM
Yes Mike, 2mm sheet stainless. I traced the curve of the star to get the shape. The centre-centre distance is the same as a stock lever. Actually didn't take too long to make.
Title: Re: The Jigmaster Project
Post by: mo65 on November 30, 2016, 05:41:10 PM
Love this thread Rothmar2...great work! 8)
Title: Re: The Jigmaster Project
Post by: Rothmar2 on December 10, 2016, 06:58:47 PM
A little more to add. I made a rough knob for the Cortez build out of some PVC stock I bought away with me, just to get an idea of what a knob would feel like. Only took 15mins to spin it up. I think I prefer T-bars. Just a personal thing I think, probably from using large lever drags for a lot of my fishing over the years. Back to the drawing board and lathe.....

(http://alantani.com/gallery/21/10783_29_08_17_2_25_45_215741584.jpeg)

And the composite rod clamp is done for the 500. I ended up putting another layer of carbon fibre tape over the whole piece as I had a little rub through to the polyester/fibreglass core when I did the first round of fairing. I then built up the epoxy thickness over the second layer of CF tape, and then faired and polished it up. Result....

(http://alantani.com/gallery/21/10783_29_08_17_2_25_51_215754.jpeg)

I don't have the 500 with me at the minute, but will show it completed when I get home in a few weeks. This clamp is the last piece for it. I'm hoping I'll have the Cortez build done as well as the fishing will be hotting up when I get home, and hopefully I'll be able to break both of them in. I've also been chipping away at a couple more frames while I've been out here, these will be the last of the jigmaster frames that I'll do.

Thanks again for all the words of support.
Title: Re: The Jigmaster Project
Post by: Bill B on December 10, 2016, 07:51:50 PM
Outstanding work brother....that knob reminds me of the wheels on the kids skateboards....hmmmm might have to take a look at those wheels....two bearings and soft urethane.....interesting concept.....Bill
Title: Re: The Jigmaster Project
Post by: Alto Mare on December 10, 2016, 10:39:03 PM
You keep on adding Chris, while we sit back and enjoy the show. :)

Very nice!
Title: Re: The Jigmaster Project
Post by: broadway on December 11, 2016, 04:31:27 AM
Chris,
   You haven't stopped impressing me, WOW! You do some beautiful work.
How is the counter weight on the handle attached.  Is that "pin head" a rivet?
Awesome job, bud!
Dom
Title: Re: The Jigmaster Project
Post by: Rothmar2 on December 26, 2016, 02:51:49 PM
Dom, the counterweight is screwed on with a M5 thread. The little bit in the centre is just left over from when it was turned on the lathe. I'll eventually do away with the bolt through crank arm, and just Loctite an M5 stud into the counterweight and fair it flush with the back of the crank.

(http://alantani.com/gallery/21/10783_29_08_17_2_25_58_215761363.jpeg)

I've made the rod clamp from stainless, I used the tool I made for modifying the International stands for the first 501 frames to hold the piece to machine the rod profile.

(http://alantani.com/gallery/21/10783_29_08_17_2_26_37_215781557.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_2_26_31_21577280.jpeg)

And as you can see, a SS handle. It's hollow, and I've skimmed it as much as I dare. Despite this, it won't be staying on the counterweight crank, I've just mounted it for show. I've started another crank which won't be counterweighted for this handle. I did try to counterweight it, but the required weight to balance is too large, and just adds too much unnecessary weight to the whole reel. I'll probably make a black Delrin ball in future and fit it to the CW crank and eventually to the Frankenstein Jiggy.

I've also started on an ally frame which will eventually be mated with the Cortez plates. Long way off yet, I am trying to find a place where I can get the anodising done without it costing an arm and a leg. Making this frame has presented its own niggles, no problems drilling and tapping, just too easy to scratch and warp the frame's surfaces during the machining and clamping processes, despite putting thin copper sheet between the frame and clamping tools. The seat has been made from a broken alloy crow bar we had on board, its strong stuff, but have the feeling I may have to get it painted/powder coated, as anodising  won't take to certain alloys, and my gut feeling is this will be one of them. At the end of the day, no hurry at this point.

(http://alantani.com/gallery/21/10783_29_08_17_2_26_42_215791498.jpeg)

Still have some overall fine tuning of the drag stack, and find out why free-spool isn't great, plus a bit more polishing of parts. All  things I can do when I get home. Hopefully I'll get this Cortez reel, and the 500 out for breaking in soon.
Title: Re: The Jigmaster Project
Post by: mhc on December 26, 2016, 11:26:26 PM
Looking good great! It's a pity the SS grip is a bit heavy for that reel, it really suits it.
Did you end up bending the ally frame in the die you made for the SS frames?
Mike
Title: Re: The Jigmaster Project
Post by: Rothmar2 on December 27, 2016, 04:54:16 AM
Yep, bent it around the punch/die Mike. Was an 8mm ally flange from a cooling water tank that was scrapped.
Just cut the strips to bend from that. Try to utilise scrap wherever I can.
Title: Re: The Jigmaster Project
Post by: Bryan Young on December 27, 2016, 05:01:13 AM
Wow!!!
Title: Re: The Jigmaster Project
Post by: Penn Chronology on December 27, 2016, 06:23:21 AM
QuoteYep, bent it around the punch/die Mike. Was an 8mm ally flange from a cooling water tank that was scrapped.
Just cut the strips to bend from that. Try to utilise scrap wherever I can.

Very amazing work! You have old time skills. Hard to come by in today's world.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on January 02, 2017, 08:43:52 PM
Looks like an opportunity has presented itself for a shakedown of the 500 and the Cortez reels in the next couple of days. I have hastily finished the new crank for the Cortez so it's usable, but will require further finishing at another time.
These reels have been set-up for different purposes. To recap, the 500 has stock bridge, with an extra dog fitted, stock gears, stock brass drag stack, but SS 8 toothed gear sleeve and Delrin sleeved spacer, Delrin U/G washer. It also has Adam's Star. I intend to only fish this reel with 8kg test line, so maximum drag will probably only ever be 7-8lbs, well within the capabilities of the stock parts.
The Cortez has the works. BP SS 4:1 gears, bridge, jack, yoke and 10 toothed gear sleeve, self made SS spacer (no delrin sleeve.....yet), Delrin U/G washer, self made SS/Carbontex drag stack with Delrin washer on top, curved Three Se7ens star. I've spooled it up with 24kg Platypus Pretest Braid, and has about 50' of 24kg Momoi topshot. It's mounted on a custom made United Composites "Zues" PE5 rated 5'10" jig-stick, Alps reel seat, guides are "Acid Wrap" configuration. This will be a knock 'em down/drag 'em out rig for school sized tuna and reef fish. 16-18lb drag straight up.

(http://alantani.com/gallery/21/10783_29_08_17_2_26_49_21580969.jpeg)

(http://alantani.com/gallery/21/10783_29_08_17_2_27_06_215811117.jpeg)

Close up of composite reel clamp fitted

(http://alantani.com/gallery/21/10783_29_08_17_2_27_16_215821198.jpeg)

Not much chrome to peel around here!

(http://alantani.com/gallery/21/10783_29_08_17_2_27_26_215831459.jpeg)

Or here

(http://alantani.com/gallery/21/10783_29_08_17_2_27_29_215842438.jpeg)

Looking forward to making this sing

(http://alantani.com/gallery/21/10783_29_08_17_2_27_35_215851264.jpeg)

Will post up some pix if I have any joy.
Title: Re: The Jigmaster Project
Post by: Bill B on January 02, 2017, 09:27:57 PM
Good luck brother....hope you get a chance to put a hurt on some fish......Bill
Title: Re: The Jigmaster Project
Post by: Tightlines667 on January 02, 2017, 11:47:17 PM
Can't wait to see some pictures of the 'schoolies'.  

Do you have a GoPro?
*Video of your bite would be even greater.  

Hope I am not jinxing the trip here ???
Title: Re: The Jigmaster Project
Post by: Alto Mare on January 03, 2017, 12:22:30 AM
Chris, those look like they mean business, can't wait for the report...no pressure :)
Title: Re: The Jigmaster Project
Post by: Rothmar2 on January 03, 2017, 03:40:23 AM
No Go-Pro for me John, although the guy I'm fishing with films a bit with the Sony Cams, but doesn't edit much tuna footage, concentrates on swordfish clips.
I'm sensing y'all seeking a "Tankesque" style report.....gotta see how the trip pans out.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on August 30, 2017, 11:37:37 PM
Bit of an update here. 2017 has not been the greatest of years for me so far, work stress (too much), and moving around jobs, has not let me get a great deal done on this project. But there has been a bit going on behind the scenes, which I will add in time. Another Jigmaster frame and reel has been almost completed, some other parts have been made, and there has been some fishing done with these reels as well! Quite hard fishing too, which has tested these reels to the limit, and limits have been reached to the point of failure in a particular case.
For now, I have a LOT of thread post rebuilding to do,thanks to the photobucket debarcle. In this thread alone, there are approx 200+ photos. And I have other threads to repair as well. Which is going to take a lot of time. So far I have uploaded over 500 photos onto the forum Gallery, and probably still have 100-150 more to upload to rebuild all the threads and posts I have done here over the years. A big shout out to Alan T and the moderators for allowing me gallery access. I fully intend to restore as much of the photos as possible.
In the meantime, here is a little taste of what will come, but can one of the moderators please tell me how to rotate images for posting PLEASE!


Title: Re: The Jigmaster Project
Post by: thorhammer on August 31, 2017, 12:37:39 AM
Yes please do moderators. This looks like a left handed piece of art lol


Chris always love your posts. Hate you are reloading everything but I fir one appreciate it.  That great work has to live on. 
Title: Re: The Jigmaster Project
Post by: Decker on September 11, 2017, 06:14:54 PM
Quote from: Rothmar2 on August 30, 2017, 11:37:37 PM
In the meantime, here is a little taste of what will come, but can one of the moderators please tell me how to rotate images for posting PLEASE!

I honestly don't know why photo orientation gets wrong sometimes when uploading.  it happens to me, with a photo taken from my iPhone, transfer it to my PC, and post it.  I'll look into this and see if I can come up with reliable instructions.

In the meantime, I fixed the pic inyour post by downloading the photo, rotating it in Windows Photos (Win10) and uploading it again.
Title: Re: The Jigmaster Project
Post by: Tiddlerbasher on September 11, 2017, 08:21:50 PM
Yep! That's all I ever do Joe - Windows Photo viewer - Win7 and 10 and I think Vista (cough spit retch ;))
Title: Re: The Jigmaster Project
Post by: Decker on September 11, 2017, 08:25:45 PM
I found some information and started a thread about photo orientation: http://alantani.com/index.php?topic=22793.0 (http://alantani.com/index.php?topic=22793.0)
Title: Re: The Jigmaster Project
Post by: Rothmar2 on September 21, 2017, 01:23:10 PM
Thanks for the fix Joe, I think I have the hang of it.

Now to get this thread up to date. As in a previous post, while this year hasn't allowed me much time to invest in this project, there has still been progress in several ways.
I have been trying to keep up with other related projects for others who have showed me great generosity over the course of this journey.

Here is the 501N kit I did for Mike, alongside another 501 frame I was doing for a mate of mine in Tas.

(http://alantani.com/gallery/21/10783_21_09_17_4_16_07_219251190.jpeg)

A bunch of the ongoing projects as they stood earlier this year. The 501N kit is mixed up in this lot, with my "Frankenjiggy" plates mounted to it. Was using those plates as the crash test dummy before trying the Cortez Plates. There is a Cortez Squidder kit here, which will be the subject of a future thread. Without giving too much away, Tom H is a very generous class act....

(http://alantani.com/gallery/21/10783_21_09_17_4_15_14_219241554.jpeg)

Now some serious fishing has been done with these reels. My most recent trip away at work, I was able to give my Cortez Jiggy, and my mates 501 a real workout. Water depths 250-300', and bottom bouncing for various fish species. The sharks were arguably the biggest overall test, with both reels slugging it out with multiple whalers up to 7', and they both pulled up quite large leopard sharks, that would have weighed 150-200lb, although they fight like a garbage bag full of water. Sorry, not too many pics to add here.
A couple of Red Emperor.....

(http://alantani.com/gallery/21/10783_21_09_17_4_18_30_219291836.jpeg)

Chinaman Fish, also known as "Gallopers" for good reason, they punch well above their weight....

(http://alantani.com/gallery/21/10783_21_09_17_4_38_24_219331673.jpeg)

But the biggest test (and surprise!) came on my mates 501 one night. It has all Pro Challenger internals,4:1 gears, and spool.
I had caught a couple of small snapper-like fish, not quite 2lb each, and had quickly whipped them up from the depths. I was casually cranking what a thought was a third one, when it got monstered halfway up. My first thought was "Another bl___y shark!", but after a couple of headshakes, within seconds I'm relieved of 200+m of 50lb braid, and with a calm ocean, and near full moon, we can clearly see a reasonable sized billfish of some sort going beserk. We had seen a few free swimming around the boat during the days leading up to this encounter. But to actually have hooked one in the dark was quite a shock. Now the little jiggy handled this fish with ease. Yes it got quite hot, and yes, there was a noticeable bit of drag fade, but the reel at no point felt compromised. Whatever it was (more than likely a small black marlin or sailfish) soon stopped crashing all over the place, and sounded, and I began to get line steadily back. Unfortunately, being on a 98m vessel with a draught of 8m, was always going to cause some problems with manouvering, and the fish found its way under the ship, and the line ended up rubbing against the hull and breaking. I firmly believe that if this fish was hooked from a more nimble vessel, it would have been landed. When I opened the reel up after, the PC parts all still looked like new. I had around 12-14lb initial drag set. I also had one of the composite delrin spacer sleeves I have made fitted under the drag star, and that also survived intact. Big ups for the Pro Challenger parts! Now I know there are no pictures to back this tale up, but there is a new forum member here, who has now caught the Jigmaster upgrade bug since witnessing this event. Adam feel free to pipe up if necessary ;D. The only thing that put me off, was the stainless handle I made. The hollow ends were not comfortable, so ended up making some black PVC caps to round off the ends. So this is how this reel looked when handed over to my mate when I arrived home. Well broken in I think!

(http://alantani.com/gallery/21/10783_21_09_17_4_17_32_219272299.jpeg)

Now for the failure. I was breaking in the Cortez 501 in on another night, and had caught a couple of Red Emps, and had a bit of a stoush with a shark which was released. I was in the process if battling another reasonable fish, when there was a "tick" from the reel, and suddenly its jammed solid.....(!) Whatever was on the other end, got monstered by a shark, and now I'm trying to not get pulled over the side! Thankfully the line parted, but even then I had to support the spool from both sides and roll the spool with my fingers to get the remaining line back, something has seriously let go.
Opened the reel up to find this....

(http://alantani.com/gallery/21/10783_21_09_17_4_36_05_21930589.jpeg)

Drag was probably 16-18lb. A couple of PM's to Mike, who forwarded through to Randy (Vintage Offshore Tackle), and some pics of the failure point, also sent to Tiburon, and Randy has it covered! Huge thanks to you Randy and Tiburon for the replacement! Would never get that sort of integrity and generosity out here in Australia. This failure in no way reflects on Randy or Tiburon as to the quality of their parts. Can put it down to, these things occasionally happen. I swapped the PC spool from my mates reel into the Cortez for the remainder of the trip, and had no further problems.
  Soon after I get home, the spool arrives. Obviously I have been very inspired by Striper Lou's art, and just had to give it a go myself! Yes, that handle does not look in proportion to the reel. But I have big hands, and I'm "function before fashion" every day of the week. Looking forward to getting out and fishing this reel again soon.

(http://alantani.com/gallery/21/10783_21_09_17_4_36_24_2193188.jpeg)

(http://alantani.com/gallery/21/10783_21_09_17_4_36_40_21932273.jpeg)

This thread is not over by a long shot, still much more to do!
Title: Re: The Jigmaster Project
Post by: Alto Mare on September 21, 2017, 04:26:10 PM
Chris, this thread keeps getting better and better, I didn't think it could :). Interesting, on the capability of the custom Jigmaster, but at the same time, I'm not surprised.
When these gears came out, prior to manufacturing, Alan was having a hard time finding the carbon fiber washers that could handle the load. Along the way, I've destroyed many sheets for him, when I finally got close to 20lbs, Alan said that wasn't good enough, he wanted a little more. So here you have it.
We now have some good upgrades to enjoy.
I do hope one day you'll Meet up again with that Billfish.
Excellent report Chris!

About that snapped spool shaft from Tiburon, you've said it. Tiburon has been around for some time now, this appears to be just a fluke, this type of thing could happen to any manufacturer.

It was nice to see Randy get right on it and make it right.
I was customizing one of these reels for a friend and the Tiburon or Accurate spool...I don't remember which, wasn't working with the reel. Randy sent out a replacement spool within days.
Keep up your great service Randy!

Thanks for sharing Chris.

Sal
Title: Re: The Jigmaster Project
Post by: Rothmar2 on September 21, 2017, 07:53:24 PM
No problem Sal, the least I can do is share my experiences with these parts in a real fishing situation, as you have done with your testing over the years. I forgot to add that the 501 that had the billfish on, has a stock HT 100 and stock stainless washer 3 stack in it. The Penn star was screwed down as tight as possible to give the drag numbers quoted earlier. I don't think any more would be possible.
The Cortez has the 5 stack I made myself, thicknesses quoted earlier in this thread. The CF sheet I punched the drags from was bought from an EBay seller located in Australia. Those CF washers are still in good condition. I have tested that stack and have achieved  20lb against a set of scales, but that is beyond what was recently needed, and is more than I could handle without a harness for any length of time.
Looking forward to seeing how these reels put the skids on the bluefin Tuna down here. Will hopefully be able to post a report of that up soon.
Title: Re: The Jigmaster Project
Post by: Alto Mare on September 21, 2017, 08:42:47 PM
Oh I see Chris, I thought those were the 112 HX. With the exception of the six years, those are the same gears. I'm wondering if you would have had an easier time if you did have those instead.
Keep up your great work here.

All the best,

Sal
Title: Re: The Jigmaster Project
Post by: Tightlines667 on September 21, 2017, 09:01:37 PM
Nice report!

It is great to hear of the successes, and possible limitations of using these 'works of art'.  Surprising the spool shaft broke.  I don't believe these spools were not designed to be fished at these numbers, but they sure should be able to take them.

Sounds like you had plenty of action.  A night billfish hookup/fight is impressive.  I have heard of some East Coast guys actually trolling for white marlin at night, with some success.  I tried night trolling lighted moldcraft and only caught sharks.  I suppose the 'midnight sun' style lights help.to attract and hold bait/squid, and provide daytime oriented predators with enough light to feed by. 

Nice work!

John
Title: Re: The Jigmaster Project
Post by: mo65 on September 22, 2017, 02:30:59 AM
   BRAVO! Great fishin'...I love when these custom builds get fished.
Title: Re: The Jigmaster Project
Post by: Penn Chronology on September 22, 2017, 02:56:15 AM
QuoteBut the biggest test (and surprise!) came on my mates 501 one night. It has all Pro Challenger internals,4:1 gears, and spool.
I had caught a couple of small snapper-like fish, not quite 2lb each, and had quickly whipped them up from the depths. I was casually cranking what a thought was a third one, when it got monstered halfway up. My first thought was "Another bl___y shark!", but after a couple of headshakes, within seconds I'm relieved of 200+m of 50lb braid, and with a calm ocean, and near full moon, we can clearly see a reasonable sized billfish of some sort going beserk. We had seen a few free swimming around the boat during the days leading up to this encounter. But to actually have hooked one in the dark was quite a shock. Now the little jiggy handled this fish with ease. Yes it got quite hot, and yes, there was a noticeable bit of drag fade, but the reel at no point felt compromised. Whatever it was (more than likely a small black marlin or sailfish) soon stopped crashing all over the place, and sounded, and I began to get line steadily back. Unfortunately, being on a 98m vessel with a draught of 8m, was always going to cause some problems with manouvering, and the fish found its way under the ship, and the line ended up rubbing against the hull and breaking. I firmly believe that if this fish was hooked from a more nimble vessel, it would have been landed. When I opened the reel up after, the PC parts all still looked like new. I had around 12-14lb initial drag set. I also had one of the composite delrin spacer sleeves I have made fitted under the drag star, and that also survived intact. Big ups for the Pro Challenger parts! Now I know there are no pictures to back this tale up, but there is a new forum member here, who has now caught the Jigmaster upgrade bug since witnessing this event. Adam feel free to pipe up if necessary Grin. The only thing that put me off, was the stainless handle I made. The hollow ends were not comfortable, so ended up making some black PVC caps to round off the ends. So this is how this reel looked when handed over to my mate when I arrived home. Well broken in I think!

Fantastic test and proof that your workmanship and design is amazing. Great job!!
Title: Re: The Jigmaster Project
Post by: aking65 on September 23, 2017, 06:03:58 PM
Hi readers, attached is a photo of Chris hooked up to the billfish he was talking about. It's starting to run deep and peel some line off after the surface acrobatics.
Chris is right about catching the upgrade bug. After seeing his bulletproof reels in action,  I picked up a 501 off Ebay and have fitted a SS gear sleeve, CF drag washers and changed out the screws with SS ones. In the middle of making up some posts similar to Mike's, then will get onto making a SS seat from some scrap pipe I picked up.
Also picked up a Senator 4/0 113HLW cheap, so will probably start doing that one as well.
Can see a lot of hours drilling, filing and polishing coming up.
Adam
Title: Re: The Jigmaster Project
Post by: Rothmar2 on September 23, 2017, 08:28:58 PM
 :D Adam, I had forgotten you took that pic! Make sure you post a few pics of what you come up with for the parts your making. At least you won't have to fight me for lathe time this swing away, ;D. I hope you get to catch a few fish with your 501 too.

Mike C, a few pages back, you did tell me to go catch a billfish with the reel I was making. I have at least hooked one. You must have a good crystal ball at your place, along with all your fantastic reels!
Title: Re: The Jigmaster Project
Post by: aking65 on September 23, 2017, 09:26:06 PM
Will do Chris. Bit limited on what I can do. The 2.6mm drills, new Double dog bridge and 113 arrived at home a couple of days after I flew out.
The 501 is in bits and we are in a new location, so haven't got a line wet yet.
Title: Re: The Jigmaster Project
Post by: mhc on September 24, 2017, 08:37:16 AM
Quote from: aking65 on September 23, 2017, 09:26:06 PM
Will do Chris. Bit limited on what I can do. The 2.6mm drills, new Double dog bridge and 113 arrived at home a couple of days after I flew out.
The 501 is in bits and we are in a new location, so haven't got a line wet yet.

Welcome to the site Adam, it's good to have another person on-board interested in making custom parts. I'm looking forward to seeing your creations.


Chris, I know you had told me about the 501 field testing, but it's good to read the reports again - thanks for sharing.

Mike
Title: Re: The Jigmaster Project
Post by: Alto Mare on September 24, 2017, 10:02:01 AM
Nice to have you here Adam, enjoy your stay!

Sal
Title: Re: The Jigmaster Project
Post by: Penn Chronology on September 28, 2017, 02:23:56 PM
QuoteMike C, a few pages back, you did tell me to go catch a billfish with the reel I was making. I have at least hooked one. You must have a good crystal ball at your place, along with all your fantastic reels

Hello Chris,

That is the test and you now have a Jigmaster 501 capable of Bill fishing. Seems you have created a bullet proof Jigmaster beyond the expectations of any other builder.

Your one complaint was the weight of the reel. Weight problems are usually solved by changing the base material of the build. I wonder,,,,,,,,,,,,,,,,, how about ""Titanium"". Some of you processes and techniques would have to be altered in order to deal with the Titanium but your end result would be a Jigmaster with the corrosion resistance and strength of stainless steel and the weight of aluminum. Even if you only made the side plates from Titanium, it would get you on the path of the Nirvana of Jigmaster 501's (ha, as if you have not arrived at Nirvana already with your stainless steel version)........  ;)

Only a suggestion. ::) You do some amazing work. You have skills that go back to the industrial age. Good to see that in today's world.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on December 21, 2017, 11:50:18 AM
A little more to add....

Mike C, Titanium! now we really are getting into big dollar territory! Would hate to think what the cost would be for raw materials to machine a set of plates from billet, and plate to bend frames from. But such a reel would survive decades of years of use with a bit of care.

There will be no more SS jigmaster frames from me. All the tooling I made now resides at the bottom of the Indian Ocean. Long story not for here. I do have a couple of Aluminium frames bent, which I will get to soon. One will eventually support the Cortez Plates. Have got onto a place to get the anodising done when I have finished carving out the frame.

Have cleared a few jobs recently, and have had some time to get back onto my own gear. Inspired by Ted's clutch levers, and Mike (mhc) having made an SS piece from a blank I sent to him, it was about time I made one for myself.

(http://alantani.com/gallery/22/10783_21_12_17_4_07_10_22879359.png)

(http://alantani.com/gallery/22/10783_21_12_17_4_07_23_22879334.png)

(http://alantani.com/gallery/22/10783_21_12_17_4_07_37_228812072.png)

Took a lot longer to make than previous levers I have done. But it was well worth it. Absolutely love the extra purchase gained by the wider section lever. Hat's off to you Ted! A great concept.

This lever kind of symbolises the many influences that have inspired me during this project. Alan C, Adam's, Tom H's SS parts and designs. Sal bringing delrin into the mix (stopper is made from delrin), and his help behind the scenes. Ted's rethinking design, and coming up with his own range of upgrade parts. And the help from Mike (mhc) with part procurement, and original concepts and fabrications, that he has shared with us all.

With our offshore fishing season about to get into full swing, hopefully there will be some fishing done with these jigmasters again soon.



Title: Re: The Jigmaster Project
Post by: Alto Mare on December 21, 2017, 12:59:53 PM
Chris, I'm surprised you're not designing for Penn yet, that's one of the best eccentric lever I've seen.
I do have one miner criticism :), try flipping the star and let's see it again, I bet it will look even better.
Excellent work as always, Chris.

Best,

Sal
Title: Re: The Jigmaster Project
Post by: Rothmar2 on December 21, 2017, 06:45:43 PM
I've got to hand it to you Sal, there is not much that gets by you! Mike (mhc) will be laughing when he see's this. I had already 'fessed up to him over the phone. The lever is actually a ball-up. I wasn't thinking when I traced Adam's star arm onto the lever blank, nor was I thinking when I picked up the hacksaw to start carving it out. This is probably a symptom of how many of the parts I make are made. Doing an hour here and there, in between everything else I have to do, wife, kids, chores etc.
So focus can be lost at times. I like the way the star is currently orientated. It is more comfortable to crank the star down, as you don't get a pressure point on your fingers from the tip of the star. When backing off, your fingers naturally (for me a least) seem to rest a bit further towards the centre of the star away from the tip.
At the end of the day, I'm not really worried. Maybe some day I'll get around to shaping another lever, with the curvature the correct way to match the star. Maybe not.....
Title: Re: The Jigmaster Project
Post by: Alto Mare on December 21, 2017, 06:52:17 PM
 :D :D...just messing with you Chris, you're too perfect. I'm just trying to find something, but not able to :)
Title: Re: The Jigmaster Project
Post by: Rothmar2 on December 21, 2017, 06:59:34 PM
Well played Sal! I got pants'd big time. Too funny!
Title: Re: The Jigmaster Project
Post by: Maxed Out on December 22, 2017, 01:01:10 AM
 Sorry to hear about your hard work sitting on bottom of the ocean.

 I love the curved shape of the shift lever. It gives it a very smooth sexy modern appearance, plus it just looks bad to the bone !!....but we all know the most important feature is function first and foremost. The wider body of the lever makes shifting so much easier. No more fumbling for the little bump on the top when your fingers may be half numb or slimy from bait or fish. The material you used will outlast father time.

Thanks for sharing all your exceptional knowledge and talent and can't wait to see what's next, but somehow you always continue to raise the bar and have no doubt the wheels are turning on the next surprise....I'll be patiently waiting !!

 Merry Christmas from across the pond

Ted
Title: Re: The Jigmaster Project
Post by: broadway on December 22, 2017, 03:24:34 AM
Chris,
   You never cease to amaze me.  That is one cool looking shifter obviously modeled after Ted work of art with a nice curve to it.
When I read that your tooling is sitting at the bottom of the Indian Ocean I was first curious to hear the story, and then I realized maybe you weren't the one who threw it overboard. :-\
Like Ted said, sorry to hear that!
I can;t imagine what you would come uo with if you had more time.
Thanks for showing what's possible,
Dom
Title: Re: The Jigmaster Project
Post by: mhc on December 22, 2017, 12:57:17 PM
Quote from: Rothmar2 on December 21, 2017, 06:45:43 PM
I've got to hand it to you Sal, there is not much that gets by you! Mike (mhc) will be laughing when he see's this.

Correct! When Chris told me he cut the curve in the 'wrong' direction I (like Sal) suggested turning the star over so they would both be in the 'wrong' direction. Chris wasn't keen on that idea so I then suggested the curves are subtle and that it wouldn't be noticed anyway...... looks like I was wrong!  ;D ;D

Mike
Title: Re: The Jigmaster Project
Post by: Alto Mare on December 22, 2017, 01:18:29 PM
Quote from: mhc on December 22, 2017, 12:57:17 PM
Quote from: Rothmar2 on December 21, 2017, 06:45:43 PM
I've got to hand it to you Sal, there is not much that gets by you! Mike (mhc) will be laughing when he see's this.

Correct! When Chris told me he cut the curve in the 'wrong' direction I (like Sal) suggested turning the star over so they would both be in the 'wrong' direction. Chris wasn't keen on that idea so I then suggested the curves are subtle and that it wouldn't be noticed anyway...... looks like I was wrong!  ;D ;D

Mike
:D :D...
I'm thankful for most members here, especially you two...Merry Christmas guys!

Sal
Title: Re: The Jigmaster Project
Post by: Bryan Young on December 22, 2017, 04:25:31 PM
Chris, that is simply amazing.  Thank you for sharing.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on February 28, 2018, 11:04:50 AM
I have almost finished an aluminium frame to go with my Cortez plates. Just got to finish the polishing then its off to an anodizer to get a clear coat for the frame, and will probably get black done for the reel seat. Am thinking I will go a black spool, and have some black/white acrylic swirl stock to remake the handle to tie it all together. That will see this reel finished. The stainless frame will then got to the Franken-jiggy, and have a few things to do to that before it will be complete.

Could one of the moderators please fix the photo orientations?...still having all sorts of trouble with that. I wish that rotation function actually worked in the Gallery Pic. Editor. Thanks in advance.

(http://alantani.com/gallery/23/10783_28_02_18_1_45_41_23698572.jpeg)

(http://alantani.com/gallery/23/10783_28_02_18_3_41_39_237002019.jpeg)
Title: Re: The Jigmaster Project
Post by: Alto Mare on February 28, 2018, 12:34:05 PM
Gorgeous Chris! one of the best frame I've seen
(https://i.imgur.com/SiqHUaC.jpg)
(https://i.imgur.com/MyQQnEX.jpg)

Keep up your great work!...and thanks for making us part of it.

Sal
Title: Re: The Jigmaster Project
Post by: mhc on March 05, 2018, 11:08:33 AM
The polishing is coming along nicely, it's looking great! That will be a pretty solid base for your Cortez plates - I'm looking forward to seeing it and the franken-jiggy side by side, they will make an awesome pair.
Thanks for keeping us up to date with your epic Jigmaster project(s).

Mike
Title: Re: The Jigmaster Project
Post by: STRIPER LOU on March 05, 2018, 12:53:03 PM
Very nice Chris! Looks good in either direction. Great work!

...............Lou
Title: Re: The Jigmaster Project
Post by: Tiddlerbasher on March 05, 2018, 01:50:03 PM
Lovely work Chris
Title: Re: The Jigmaster Project
Post by: Rothmar2 on March 05, 2018, 08:47:15 PM
Thanks chaps and to Sal for the photo fix. Off to the anodisers this morning, see how it comes out. Will post up some pix when I get the frame back.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on March 09, 2018, 09:30:22 AM
The Cortez Jiggy got a bit of a workout on Wednesday, with a trip to the far SW Islands of Tasmania that make up the Maatsuyker Group. A 65lber was bought to the boat in under 10mins, with the drag pretty well buttoned down. We had a couple more bluefin on the Jiggy reel, but hooks pulled soon after the strike, probably due to running a too-short a mono top shot.
On the same day, my fishing partner broke a reasonably long standing 8kg test Bluefin State record by landing a 32.7kg model after 2 and 3/4hrs (Reel was a Shimano TLD 15). Between the 2 of us we actually beat the previous record 3 times over on the day, but Simon's fish will hopefully go to the books after the paperwork and testing has been submitted.

A couple of pix of the Cortez in action. I'd have more but still having trouble with photo orientation.

(http://alantani.com/gallery/23/10783_09_03_18_12_50_17_238691773.jpeg)

(http://alantani.com/gallery/23/10783_09_03_18_12_50_26_238701113.jpeg)

No word from the anodizer as yet about the ally frame.
Title: Re: The Jigmaster Project
Post by: mhc on March 09, 2018, 12:34:05 PM
Another solid workout for your upgraded jigmasters Chris, good to see all your work has been worthwhile.

Mike
Title: Re: The Jigmaster Project
Post by: Alto Mare on March 09, 2018, 01:43:09 PM
Excellent report on your masterpiece Chris, with some nice fishing to boot. Must give you great satisfaction bringing in that type of fish with something you've created.
Keep up your excellent work and thanks for sharing it with us.

Best,

Sal
Title: Re: The Jigmaster Project
Post by: Tightlines667 on March 09, 2018, 04:49:29 PM
Quote from: Rothmar2 on March 09, 2018, 09:30:22 AM
The Cortez Jiggy got a bit of a workout on Wednesday, with a trip to the far SW Islands of Tasmania that make up the Maatsuyker Group. A 65lber was bought to the boat in under 10mins, with the drag pretty well buttoned down. We had a couple more bluefin on the Jiggy reel, but hooks pulled soon after the strike, probably due to running a too-short a mono top shot.
On the same day, my fishing partner broke a reasonably long standing 8kg test Bluefin State record by landing a 32.7kg model after 2 and 3/4hrs (Reel was a Shimano TLD 15). Between the 2 of us we actually beat the previous record 3 times over on the day, but Simon's fish will hopefully go to the books after the paperwork and testing has been submitted.

A couple of pix of the Cortez in action. I'd have more but still having trouble with photo orientation.

(http://alantani.com/gallery/23/10783_09_03_18_12_50_17_238691773.jpeg)

(http://alantani.com/gallery/23/10783_09_03_18_12_50_26_238701113.jpeg)

No word from the anodizer as yet about the ally frame.

Great!

Was the TLD stock?

John
Title: Re: The Jigmaster Project
Post by: Decker on March 09, 2018, 04:54:22 PM
Quote from: Rothmar2 on March 09, 2018, 09:30:22 AM

A couple of pix of the Cortez in action. I'd have more but still having trouble with photo orientation.


Chris, this is great!   Sharing your reel-crafting process, and then the catch.   Helps a Yankee get through the winter!

The photo-orientation thing is a pain.   I posted some technical information about it, and will put it here later when I find the post.  Basically there is orientation data stored by your camera on each photo, so that the photos can be stored uniformly.  This is done for efficiency in recording/storing the photo files.  Some programs read this orientation data; some do not.  The code used to display our web pages on the site does not.

The simplest solution that I know of is to import all the photos to your PC, then run a program that reads the orientation data, and rearranges the physical orientation of the photo file - i.e. landscape is stored as landscape, and portrait as portrait.  I'll get the name of a program later and post here.  What is nice about this type of program is that you can run it against hundreds of photos in one sweep.

If there is only one or two photos you want to fix, you can generally open the photo in Windows Photo (or Photo Editor), make some change, set the orientation you would like to see, and save the changes.

Cheers,

/Joe

UPDATE: This article explains the EXIF orientation coding well, and offers some solutions:  https://www.howtogeek.com/254830/why-your-photos-dont-always-appear-correctly-rotated/
Title: Re: The Jigmaster Project
Post by: Rothmar2 on March 09, 2018, 07:57:06 PM
Thanks Joe for the reminder, I will get onto it soon. Had a couple of hard days since this fishing day. I got back into phone range from this trip to find out my 17 yo daughter was in hospital with possible breast cancer. Fortunately she has been cleared of that, but will still require surgery on Tues to remove the benign growth in her chest. So a stressful week ahead.
John, stock TLD's but prepped as per the site mantra. Although Simon is asking for me to make custom T-bars after the extended battle!
Title: Re: The Jigmaster Project
Post by: bhale1 on March 10, 2018, 02:56:50 AM
Chris,
Great work and great fishing pics.....but I just wish you and your daughter the best...scary!!!!!!
Brett
Title: Re: The Jigmaster Project
Post by: Tiddlerbasher on March 10, 2018, 01:41:32 PM
Thanks for the ride Chris.
So sorry to hear about your daghter, at leat it's not the big 'C'. Worrying times. I remember when my wife was diagnosed with cancer. She is now a 20yr survivor :)
Title: Re: The Jigmaster Project
Post by: STRIPER LOU on March 10, 2018, 02:07:38 PM
Hey Chris,

I'm very sorry to hear about your daughter. So glad to hear its benign! Man, that's some scary stuff. There's some great doctors and procedure these days and I'm sure everything will work out fine.

Please keep us posted and all the very best to you and your family,  ..  Lou
Title: Re: The Jigmaster Project
Post by: Decker on March 10, 2018, 03:12:02 PM
Prayers for you and your daughter, Chris! 
Title: Re: The Jigmaster Project
Post by: mo65 on March 10, 2018, 03:23:13 PM
   I hope all goes well for your daughter Chris.
Title: Re: The Jigmaster Project
Post by: Florida Cracker on March 28, 2018, 11:53:53 AM
WOW! Awesome job!.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on March 31, 2018, 07:10:23 AM
Hi Everyone,

Thanks for all the thoughts for my daughter. She has amazed my wife and I with her resilience through all this. The surgery went very well and the benign growth removed. While she still has a bit of an ache from where the lump was removed from, she is almost back to normal. The surgeon has said less than 5% chance of re-occurrence, so glad to have put this behind us.
As for the frame, I have it back from the anodiser, and I will get some pics of the assembled reel up ASAP. Still have trouble with the photo orientation though....
Title: Re: The Jigmaster Project
Post by: Jerseymic on April 01, 2018, 08:58:36 AM
Prayers for your family Chris.

Mike.
Title: Re: The Jigmaster Project
Post by: STRIPER LOU on April 01, 2018, 02:22:00 PM
Excellent Chris! Please keep us posted with any news as to how the healing is going.

Wishing you and your family all the best,  ..  Lou
Title: Re: The Jigmaster Project
Post by: Rothmar2 on April 21, 2018, 09:51:47 PM
I would just like to say a big thank-you to all those who have posted Well Wishes here about my daughters scare. She has fully re-covered and is back to her usual self. There is almost no scarring, and she is not actually worried about the minimal one she has. With all this modern day "body image" thing that teenagers go on about, I think she has shown maturity beyond what we though she was capable.

Anyway, finally got around to getting some photos up of the frame as it came back from the Anodiser. At first I was a bit bummed about the matte finish, but after mounting the Cortez plates to it, I actually quite liked it.

(http://alantani.com/gallery/24/10783_21_04_18_2_37_09_24303628.jpeg)

(http://alantani.com/gallery/24/10783_21_04_18_2_20_35_242961724.jpeg)

(http://alantani.com/gallery/24/10783_21_04_18_2_35_49_243021136.jpeg)

When I next get home, I will be finishing the black/white acrylic swirl T-bar to replace the pictured one, which will finish this particular Jigmaster right off.
Title: Re: The Jigmaster Project
Post by: Alto Mare on April 21, 2018, 10:05:17 PM
Chris, first I'm glad everything is back to normal with your daughter...great news!
I agree on the matte finish, it looks really good with Tom's plates.
May I ask what is the matter with that blue knob? I think it looks great on that reel.
Are you making those yourself?

Best,

Sal
Title: Re: The Jigmaster Project
Post by: Rothmar2 on April 21, 2018, 10:47:51 PM
Cheers Sal. Yes I am making the handles myself. Got inspired by Lou's art, and have taken on doing a few, but in my own way. The Blue one does look OK, but I think you'll agree when you see it, that it's replacement will tie in better. I also want the next one to be a bit smaller in diameter, only by a couple of millimeters. The Blue feels good in the hand, but I think I can improve it a bit more. It's all learning/progression!
Title: Re: The Jigmaster Project
Post by: mhc on April 21, 2018, 11:18:43 PM
Good to hear your daughter has fully recovered, she must have inherited a bit of your resolve.
I like the matte finish as well, it looks ready for work - I think I'll try bead blasting a SS part to see it gives a similar finish.

Mike
Title: Re: The Jigmaster Project
Post by: thorhammer on April 22, 2018, 02:24:04 PM
Hey Chris, I'm late to this one but glade to hear your daughter is back up to snuff!


John
Title: Re: The Jigmaster Project
Post by: mike1010 on April 22, 2018, 03:36:37 PM
Chris, had not seen the post about your daughter's illness until now, and add my voice to those cheering the happy outcome.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on September 17, 2018, 11:22:37 PM
Well this project is coming to an end. I have been chipping away at this project slowly since my last post. I obtained some more acrylic stock in black/white swirl from DuckCalls USA off the big auction site, to tie in with the black spool. I added a little more profiling to the handle where the thumb rests for a bit more comfort. Result

(http://alantani.com/gallery/25/10783_17_09_18_5_43_23_254781594.jpeg)

(http://alantani.com/gallery/25/10783_17_09_18_5_43_08_254771225.jpeg)

So the Cortez plated reel is now completed in full.

(http://alantani.com/gallery/25/10783_17_09_18_5_43_52_25479874.jpeg)

(http://alantani.com/gallery/25/10783_17_09_18_5_44_16_254801324.jpeg)

I also created another handle for my mates Jigmaster to replace the stainless one it had previously, which I was never entirely happy with. He also when for the thumb rest on the overall shape, which we did with him present, until he was completely happy with the feel. This reel may get a few extra parts in the future, but for now it will stay as is.

(http://alantani.com/gallery/25/10783_17_09_18_4_41_29_25453380.png)

(http://alantani.com/gallery/25/10783_17_09_18_4_40_00_25452462.png)

(http://alantani.com/gallery/25/10783_17_09_18_4_43_30_254602321.png)

The "Franken-jiggy" is now ready to fish. The combination of Jig and Surfmaster plates, PC internals, and other self made parts is the reason for the monicker. It has the SS 501 frame that the Cortez plates were once on. I also made another delrin sheathed spacer sleave, spun up on my mini-lathe

(http://alantani.com/gallery/25/10783_17_09_18_5_56_21_254821240.jpeg)

The reel clamp was short-cutted somewhat. I found a block of black polyethylene at the tip and figured this would do for a clamp. It was far less arduous to machine, and well within the capabilities of my mini-lathe. Much easier to make than the composite or stainless clamps I have made for other reels in this project. The clamp studs and recessed nuts were also made for the over-all assembly

(http://alantani.com/gallery/25/10783_17_09_18_5_39_48_254691915.jpeg)

The counter-weighted crank was made quite a while ago, and I wanted to give the ball handle a go. I got a large PC ball sent over and called it done. I did have intentions of making my own ball, but I have lost access to the big lathes needed when I lost my job with a previous employer. I'm not entirely sold on the look of this assembly, its "bitsy" for my taste, but I will at least fish it to see how it feels in a real situation. I have contacted Ted to get one of his designed handle/cranks sent over when they become available again. Black and white of course! Easy enough to switch if the ball doesn't suit. Ted and Adam (3 Sevens) had influence in the clutch lever I made for this reel as well.

(http://alantani.com/gallery/25/10783_17_09_18_5_40_23_254702079.jpeg)

(http://alantani.com/gallery/25/10783_17_09_18_5_42_41_25476507.jpeg)

(http://alantani.com/gallery/25/10783_17_09_18_5_41_49_254721205.jpeg)

(http://alantani.com/gallery/25/10783_17_09_18_5_42_31_254752062.jpeg)

(http://alantani.com/gallery/25/10783_17_09_18_5_42_14_25474566.jpeg)

(http://alantani.com/gallery/25/10783_17_09_18_5_42_01_25473552.jpeg)

The clicker assembly in the Surfmaster plate was is good condition so there is no need to change it for now. I do have a mag kit to fit as well, but its highly unlikely this reel will be used for casting for the style of fishing I do.
Our offshore season will fire up again soon, so hopefully I will get a chance to put these reels through their paces.
For everyone who has followed this thread, thanks again for your interest. I hope this has inspired some of you to create some parts with your own handi-work. This thread should not take away from the large amount of upgrade parts that are available through the vendors who have put a large amount of time and money into bringing these parts to us. Respect to all of them!
Title: Re: The Jigmaster Project
Post by: thorhammer on September 17, 2018, 11:58:52 PM
Chris, absolutely fantastic, and certainly inspiring! Your last paragraph sounded a bit too much like a eulogy for my taste; you have to keep it going or else start another project for us!!!!


John
Title: Re: The Jigmaster Project
Post by: Rothmar2 on September 18, 2018, 05:27:33 AM
There will be other projects soon John that I will get threads going on. I actually have started on Tom H's Squidder kit that he generously sent me a couple of years ago. Mike has been decent enough to send me all the parts to assemble the reel, but I have some plans to add my own touches to it. I also have started a 349 build, I actually have some photos already in the gallery for it, but will get a thread going for that one when I'm next back from work. The old Daiwa project thread will also re-surface, have had a bit of a change in direction with how that was going to be done, since seeing some of Marq's carbon fibre work, and Mike sending me a heap of woven carbon fibre that he never used on his Penn cut-down project threads.
So one project ends, and 3 begin! I also have a few other reels boxed up that will be getting mods down the track, but they are a long way off yet.
Title: Re: The Jigmaster Project
Post by: gstours on September 18, 2018, 05:56:36 AM
Thanks for sharing your thoughts and pictures of your work on reels and your fishing pictures. 
    We are all inspired with your work,.   Every time I see you post something I,m motivated further to do something with my hobbies and tools in my shop.  Truly thanks.   Keep up the great work.   And posting.🚣‍♂️
Title: Re: The Jigmaster Project
Post by: Darin Crofton on September 18, 2018, 06:43:00 AM
I'm blown away at this thread, just read every word and comment. Chris, your work here is nothing short of amazing! Thank you for sharing!!!
Title: Re: The Jigmaster Project
Post by: mhc on September 18, 2018, 10:07:44 AM
That's a very impressive set of unique 501s - the frames speak for themselves, but all the other custom parts really finish them off - the wide eccentric levers, handles with tailor-made grips, rod clamps, drag stars etc.
They are a fitting finale to what has been an epic thread - running for over three years with fascinating twists and turns the whole time as you developed and improved on the concept as you went. I feel privileged to be custodian of a few spin-offs (pardon the pun) from this project. Thanks for the sharing the project with us, and thanks a million for the frames, rings and other parts along the way, and, not least of all - the inspiration to experiment with reels.

Mike
Title: Re: The Jigmaster Project
Post by: Alto Mare on September 18, 2018, 10:32:40 AM
Chris, it is easy to figure out why you have over 100.000 views on this amazing thread, don't ever give up!

I always enjoy your postings...thank you!


Sal
Title: Re: The Jigmaster Project
Post by: Decker on September 18, 2018, 11:36:17 AM
 :o W O W ! :o
Title: Re: The Jigmaster Project
Post by: Rothmar2 on November 14, 2018, 06:18:20 AM
Just a quick post to show that I am getting some fishing done with these reels now that they are (almost) finished.
Had a day trip up the east coast of Tasmania, after hearing a few reports that the Striped Trumpeter were biting well after their closed season. I have previously mentioned these fish in the Tank's World Tour thread.
Managed to get onto a few, with one decent one testing the Cortez a bit. We were fishing a deep reef at about 270', first mark produced nothing, but the second marked turned it on the moment the baits reached the bottom. A 5kg model was first up, and while it put a good bend in the rod, it didn't gain any line.

(http://alantani.com/gallery/25/10783_13_11_18_6_43_27_259171256.jpeg)

The next drop, I hooked a good-one, which while playing up a lot, was only able to pull about 15' off the reel, against approx. 7kg drag. The fish went on to be about a 7kg model, and normally these will bulldog a fair bit of line off most tackle.

(http://alantani.com/gallery/25/10783_13_11_18_6_43_06_259152029.jpeg)

We then pulled a couple of undersized ones, which were returned to the water, and the school we marking shut-down straight after. We moved off to some other marks a couple of miles away, and managed some smaller eating species, before going back to the mark with the hot running stripeys at the change of tide.
Once again, bites as soon as hitting the bottom, but one marginal keeper, and two undersized were raised, and just like first time, when they were returned, the school shut down again. No matter, we had a decent feed anyway.
The Cortez performed well, I placed a minute amount of lapping paste on the 5:1 gears prior to the trip and this smoothed things out dramatically over the day of winding. The only other thing to note was I was not entirely happy with the shape and feel of the black/white swirl handle during the reel fishing situation. This will be modified ASAP, and will show the results when done.

Title: Re: The Jigmaster Project
Post by: Darin Crofton on November 14, 2018, 06:24:14 AM
Great catches, dinner is now served!
Title: Re: The Jigmaster Project
Post by: mhc on November 14, 2018, 08:47:38 AM
Nice catch Chris, it's good to see the custom jigmasters in action - bringing those stripey things up from 270' would have been a good workout for the PC 5:1 gears. Thanks for posting the follow up report on how your reels are performing.

Mike
Title: Re: The Jigmaster Project
Post by: Alto Mare on November 14, 2018, 10:50:15 AM
Nice Chris, I bet that's a good tasting fish. With so much going on our site, I have forgotten all about that custom handle you made and now I feel somewhat embarrassed for even attempting to send you one of mine :)... My work don't even come close to yours.
By the way, what didn't you like about the feel while fishing? I did notice that tilting the longer knobs do feel much better and I'm now setting many that way, mine are at a 10 degrees tilt.
Thanks for the report on custom parts, I'm glad everything worked out,

Best,

Sal
Title: Re: The Jigmaster Project
Post by: gstours on November 14, 2018, 02:56:19 PM
  Thanks for sharing your photos,  the proof of all your labor is in that pudding.  Nice fish too!   Thanks. :)
Title: Re: The Jigmaster Project
Post by: Rothmar2 on November 15, 2018, 01:25:31 AM
Quote from: Alto Mare on November 14, 2018, 10:50:15 AM
Nice Chris, I bet that's a good tasting fish. With so much going on our site, I have forgotten all about that custom handle you made and now I feel somewhat embarrassed for even attempting to send you one of mine :)... My work don't even come close to yours.
By the way, what didn't you like about the feel while fishing? I did notice that tilting the longer knobs do feel much better and I'm now setting many that way, mine are at a 10 degrees tilt.
Thanks for the report on custom parts, I'm glad everything worked out,

Best,

Sal


Hi Sal,

The thing I didn't like was the rest for the thumb, I just didn't judge the angle very well while trying it out in the shed. It seems as though when you are on the water, things change a bit from flat stable land. I hope the following will explain....

You can see from this shot that the thumb rest flat is about 90 degs to the handle shaft axis

(http://alantani.com/gallery/25/10783_17_09_18_5_43_23_254781594.jpeg)

While the T-Bar was faired smooth, there was a ridge under my thumb that when on the boat, was putting a line of pressure under my thumb pad. Not uncomfortable, just annoying, and I figured I can fix this.

So laying some 40 grit paper on a bench, I sanded a bit more off the handle at about 45degs. You can see it in the next few shots...

(http://alantani.com/gallery/25/10783_14_11_18_6_03_56_259231438.jpeg)

Stating to fair back with finer grain wet/dry sandpaper

(http://alantani.com/gallery/25/10783_14_11_18_6_03_21_259201596.jpeg)

The arrows should clear up the direction of the extra taper for the thumb to rest on

(http://alantani.com/gallery/25/10783_14_11_18_6_03_52_259221148.jpeg)

And all polished back up after about an hours work.

(http://alantani.com/gallery/25/10783_14_11_18_6_03_26_259201416.jpeg)

Will see how it goes on the next trip.

Sal, I'll have to disagree on your knobs, casting the blanks for shaping is next level. I have wondered how you guys casting your own get the amazing patterns in them, without the resins becoming to homogenus in colour. Some of the colours you have come up with have been amazing. The red and black ones you showed recently are stunningly beautiful. You and Lou are really setting the pace with the custom knobs you are creating.

Here is the limit of my resin casting skills. With tuna season just around the corner, I have been back making resin heads for trolling lures again, for myself and my fishing mates. Haven't done this for a few years, but needed some smaller ones to go after some light tackle records, after some heavy losses the last couple of seasons.

(http://alantani.com/gallery/25/10783_14_11_18_6_04_18_25925181.jpeg)

(http://alantani.com/gallery/25/10783_14_11_18_6_04_11_2592491.jpeg)

Should be swimming a few off the end of the Jigmasters and light tackle gear soon!
Title: Re: The Jigmaster Project
Post by: Dominick on November 15, 2018, 01:32:09 AM
Chris, nice job on those stripers.  I really like the lures.  For a while I could not resist buying ones that appealed to me.  That did not mean the fish liked them.  At least I have a bunch to change out when the fishing is slow in the hopes of finding the right color that the fish cannot resist.  You are a very talented guy.  Dominick
Title: Re: The Jigmaster Project
Post by: Alto Mare on November 15, 2018, 01:24:40 PM
I see what you mean Chris, I'm sure it will get fine tuned to perfection.
Nice job on the trolling lures as well...master of all trades :).
I see you have different shapes on the head, a good way to experiment what gets it done...good work as usual.

Sal
Title: Re: The Jigmaster Project
Post by: Rothmar2 on July 27, 2019, 09:08:27 AM
I have been somewhat quiet of late on here, just not getting much time for custom reel work, just so much on, and still get a regular stream of services to do. But did get a trip away recently, and broke the Franken-jiggy in. Well my mate Simon did.

This was a couple of weeks ago, we got a break in the weather and were able to make it Pedra Branca (which I have  posted about on the Tank's World tour thread). We found a few Bluefin straight away and Frank was able to get into the action, although it was Simon's strike at the time, he says "You better take it", and I'm like "It's OK, you took the first fish honours with the 500 Jiggy, might as well keep a good thing going, it's yours". We had a 40+ lber in the boat in less than 10mins! Simon commented how lightweight the entire rig was, and how it was "Fun" to use.

(https://alantani.com/gallery/28/10783_27_07_19_1_17_31_288201924.jpeg)

(https://alantani.com/gallery/28/10783_27_07_19_1_17_43_28832561.jpeg)

Unfortunately I noticed the Handle Ball shaft had worked itself loose a bit, so it was retired Frank for the rest of the day.

We went off in search of our favourite eating fish, the striped trumpeter, and managed to find a few, even if they weren't biting well. Good table sized 8-12lbers. The Cortez Jiggy wasn't really stressed by any of the fish we landed with the drag buttoned down.I think we may have also got a Bluefin on it too during the day. No problems with it, and the recent handle Mod, felt good in the hand.

(https://alantani.com/gallery/28/10783_27_07_19_1_18_25_288331461.jpeg)

(https://alantani.com/gallery/28/10783_27_07_19_1_18_38_288341685.jpeg)

(https://alantani.com/gallery/28/10783_27_07_19_1_19_02_28835294.jpeg)

While fishing for Stripeys, we were visited by a rather large Great White Shark, around 5.5m in length, and with a huge girth. The nearby islets had a lot of young seals about, and I suspect this shark had its fill of them. I got about 5mins of footage of the encounter on my Phone, but no idea how to transfer it to the 'net. Certainly was an awesome experience, it was so close to the boat, you could touch it. Amazing creatures. Needless to say, the sea dogs didn't trouble us at all with any of our fish! I managed to put 1 min of footage up on my Instagram page however. (User chris_rothe if you are interested).

There was a fair swell running on the day, but the sea-state was otherwise calm. Got some video footage of amazing waves breaking around the islands, but will have to just put a still shot up instead.

(https://alantani.com/gallery/28/10783_27_07_19_1_19_30_28836901.jpeg)

A great day out in the Southern Ocean. One I will never forget. The Jiggy reels have certainly been worth the effort. Pack more than enough punch for the fishing I do with them.
Title: Re: The Jigmaster Project
Post by: Crow on July 27, 2019, 11:36:42 AM
Looks like you found a real pot of gold, at the end of that rainbow !!! Nice pix, and great fish !
Title: Re: The Jigmaster Project
Post by: Penn Chronology on July 27, 2019, 02:23:57 PM
QuoteA great day out in the Southern Ocean. One I will never forget. The Jiggy reels have certainly been worth the effort. Pack more than enough punch for the fishing I do with them.

Went to your Instagram page. All I can say is, ""Amazing"". The Great White was majestic. I was surprised how calm and slow he was. Just kind of cruising around your boat. Looks like you could have pet him.

The rip you were fishing near looked a bit dangerous to me. When I see waves break like that out at sea it is a tell for me to move the boat. That part of the world is very special.

Fabulous fish and great tackle. Can't ask for more than that! Thank you for sharing.
Title: Re: The Jigmaster Project
Post by: mhc on July 28, 2019, 12:03:21 AM
It's good to see your jigmasters performing so well on some decent sized fish - thanks for another great report, although I'm not to sure I'd be comfortable with a white pointer, or any shark that size hanging around the boat - even if it is pretending to be friendly.

Mike
Title: Re: The Jigmaster Project
Post by: Penn Chronology on July 29, 2019, 06:15:47 AM
https://www.facebook.com/discovertheocean/videos/579394509231999/UzpfSTEwMDAwOTAxNTYzMzk4OToyMjI2NzMzMDE3NjM3MTk4/?id=100009015633989

Great Whites can be very friendly. You just have to be a bit careful when you are petting them.
Title: Re: The Jigmaster Project
Post by: CapeFish on July 29, 2019, 07:49:27 AM
That's the equivalent of playing with a lion's testicles!!!
Title: Re: The Jigmaster Project
Post by: Caranx on July 29, 2019, 09:20:20 AM
😂😂😂😳
Title: Re: The Jigmaster Project
Post by: Rothmar2 on July 29, 2019, 09:52:03 AM
Quote from: CapeFish on July 29, 2019, 07:49:27 AM
That's the equivalent of playing with a lion's testicles!!!

:D :D :D 8)
Title: Re: The Jigmaster Project
Post by: Penn Chronology on July 29, 2019, 04:06:13 PM
 ;D ;D ;D ;D ;D ;D
Title: Re: The Jigmaster Project
Post by: Crow on July 29, 2019, 04:10:13 PM
I think I'd rather "play with the lion"....I might be able to out run him,.... for a while, .....but I know I can't outswim that shark ! :o
Title: Re: The Jigmaster Project
Post by: CapeFish on July 29, 2019, 05:28:15 PM
Trust me you are not, about as little chance as outswimming that shark  :) Its an old South African saying when someone is looking for trouble they are playing with the lions jewels  :)
Title: Re: The Jigmaster Project
Post by: Surfrat on May 13, 2020, 03:45:11 PM
Thanks for sharing your proof of all your labor.  Nice fish too!   Thanks.
Title: Re: The Jigmaster Project
Post by: Rothmar2 on May 14, 2020, 08:36:27 AM
No problem, and thanks for looking. Welcome to the Ohana.
Title: Re: The Jigmaster Project
Post by: mo65 on May 14, 2020, 01:35:31 PM
Quote from: Surfrat on May 13, 2020, 03:45:11 PM
Thanks for sharing your proof of all your labor.  Nice fish too!   Thanks.

   I'll second that motion...great fishin'! 8)