Reel Repair by Alan Tani

For Sale => Max Out with Maxed Out => Topic started by: Maxed Out on April 04, 2018, 07:10:24 PM

Title: Failure Mode
Post by: Maxed Out on April 04, 2018, 07:10:24 PM

A few of you may have noticed I pulled back on offering any custom handle assemblies. I had serious design issues that needed to be addressed and to be honest I was seriously considering that it was my time to walk away. I convinced myself that I wasn't up to the task of what I was trying to accomplish.

A small handful of forum members convinced me otherwise and inspired me to get back on the horse. It is mostly a financial decision, as there has been a lot of out of pocket expenses that have gone towards this project, and chasing good money after bad is never a good idea.

All components of my handle assembly are my specifications made into reality by a talented machinist who also specializes in assembly. we designed the aluminum log to be larger than the hole in the eva foam, and I assumed that snug fit would hold it firmly in place. I could not do actual on the water testing because our weather was so crappy for 3 months strait. I did all my test reeling in my driveway with heavy weights to test the strength of the assembly.

The first batches were very small. Less than 10 each of jiggy and 113H blades for each color. Most all of these went out to be field tested. I didn't charge a dime for most of them, simply because I wanted feedback before I was confident enough to know the new assemblies would exceed anyones expectations (my OCD at work)

  Well, thanks to some input from a few long time members I found the weak links. The most major one is the foam grip rotating on the aluminum log, thus binding the knob stem, and possibly damaging the foam. Yogi in Honolulu was a huge help and also inspired me to address this issue. It took a few days, but did come up with a solution using adhesive specially formulated for foam rubber, and the foam is now permanently attatched to the aluminum log core.

I have also come up with a procedure to fix the ones I sent out as samples (about 35-40 assemblies). If you have any of my assemblies with silver, black, or red blade, those will need to be updated with adhesive under the foam. I have got a few members to send thiers back to me to fix and send back. It's a one day turn around. Please send me a pm and I'll shoot you my shipping address.

  Thanks for all the input and inspiration from forum members, especially Yogi and Striper Lou and Randy Pauly

  Here is a pic of what happens when the foam knob shifts under a heavy load.....not good

  .....to be continued
Title: Re: Failure Mode
Post by: erikpowell on April 04, 2018, 07:20:22 PM
Bula Ted,

Tis but a flesh wound :)

Kudos to you for finding a solution and moving ahead.
There are lots of folks behind you here. You got this.

Giddy Up now bud!  ;D ;D

All the best!
Title: Re: Failure Mode
Post by: broadway on April 04, 2018, 07:24:01 PM
Happy to see you found a fix, so we can get these babies on our reels.  Looking forward to having my big paws grab something soft for reeling in 300+ feet of wire.
Thanks for building a better mouse trap,
Dom
Title: Re: Failure Mode
Post by: Reel 224 on April 04, 2018, 07:28:48 PM
Ted: You have my support as you worked out this problem (issue) and as far as i'm concerned you have made every effort to make good. I'm very pleased with the new design, it is tight and comfortable in hand> Keep up the good work.



Joe  
Title: Re: Failure Mode
Post by: thorhammer on April 04, 2018, 07:30:28 PM
Ted is on the top shelf, the Jefferson bourbon grade above Ocean. I have eight assemblies and more blades, and am sitting ready with an order for more when production is on the table, and I know other members I've spoken with are as well. They are a Cadillac piece, and I don't care that he's called me personally to get some experimental pieces back for foam glue....I'm certain I got that covered.

Dude is doing it right and knocking out the bugs in reel life, with total customer satisfaction.

If the wind ever stops in NC, I'm gonna try to break them in.


thank you my friend!
Title: Re: Failure Mode
Post by: farmer56 on April 04, 2018, 07:34:41 PM
farmer 56  here.....  WELCOME BACK.......  42   years   of  farming  has  taught  me  even in  the  darkest  hour  it's  still  best  to  climb  back  on  the  horse  ........   the  sun  will  always  shine  again....  farmer  out
Title: Re: Failure Mode
Post by: Maxed Out on April 04, 2018, 07:51:32 PM

Now with adhesive, I have tried to dislodge the foam using every bit of brute force I can apply and still no budging.

Hopefully we will soon be getting more cliff fishing feedback from Yogi.

Here is same red knob with adhesive. It looks the same, but is far more solid assembly with foam secured
Title: Re: Failure Mode
Post by: TongassFisher on April 04, 2018, 07:52:34 PM
All the Maxed out stuff I've owned has been excellent. The red light special has handled halibut into the mid 60lbs rand and is now with my 89 year old grandfather in Isla Mujeres Mexico. He tells me he has about 30 Sierra landed on it and a handful of cuda.  I'm looking forward to his 90th birthday later this year. I plan to steal that 113h from him when I'm down there.

Keep at it Ted!
Title: Re: Failure Mode
Post by: redsetta on April 04, 2018, 07:54:00 PM
Nice work Ted - great to have ya back.
All the best, Justin
Title: Re: Failure Mode
Post by: Shark Hunter on April 04, 2018, 08:01:04 PM
Ted,
You get on that Horse and Ride like the wind. ;)
We got your back.
Hopefully, I will be putting a Johnny Bench Handle to the test next week.
Title: Re: Failure Mode
Post by: Maxed Out on April 04, 2018, 08:04:10 PM
 ....also slight design change on future blades. I eliminated the countersunk area around the mounting hole to make getting wrench on the scalloped nut a whole lot easier. Also took a few thousandths off the thickness so the nut can grab more threads on the gear sleeve(Thanks Bryan for the tip)

P.S. I was also recently inspired by the Seaboy thread, so had to get in on it and built a super wide. Thanks to everyone there for the pointers about the seaboy.

 Ted
Title: Re: Failure Mode
Post by: Vintage Offshore Tackle on April 04, 2018, 08:17:08 PM
Those blades are spectacular Ted.  From the special 4/0 bars and the shift levers and color matched frame feet and rod clamps and now those super comfortable and beautiful handles, this is just the latest in a long line of great accessories that you have created to make our old Penns even more lovable for all of us.  I wish that I had half of your energy and creativity!
Title: Re: Failure Mode
Post by: Alto Mare on April 04, 2018, 08:33:50 PM
Good to see you back Ted!
Title: Re: Failure Mode
Post by: Tightlines667 on April 04, 2018, 08:55:36 PM
Welcome home my friend.  Maybe you should consider a R&D trip to the Hawaiian Islands.  My dad and his fishing buddy are planning a 10 day trip over memorial day weekend.  There is room for 1 more.

John
Title: Re: Failure Mode
Post by: Jerseymic on April 04, 2018, 09:23:55 PM
Welcome back Ted

Mike.
Title: Re: Failure Mode
Post by: Maxed Out on April 04, 2018, 10:40:07 PM

Thanks to everyone for your kindness...

...soon I'll be offering some crazy options for the knob colors...cause a little individuality never hurt  ;)
Title: Re: Failure Mode
Post by: ReelFishingProblems on April 04, 2018, 11:11:46 PM
Ted,
Welcome back and glad to see you here again.
Nick
Title: Re: Failure Mode
Post by: STRIPER LOU on April 04, 2018, 11:19:29 PM
Good to have you Back Ted! Some neato colors you have there.

Chas, one of the Commercial guys tested your handle for a little over a month and gave it a super workout. He did notice some turning on the foam but figured it came from the WD-40.

At this time of the year and if they're fishing weeks at a time they don't always make it to the cars wash so everything get doused with WD-40 for protection.
He said he cleaned it up at the truck with some rubbing alcohol and put a dab of glue on it and has been using it ever since. He liked it in the cold weather and said it still provided a decent grip even with fish slime all over it.

So that's the real test and with your changes, its all good to go!

Everything looks great and keep up the excellent work.
Regard's,  ..  Lou
Title: Re: Failure Mode
Post by: Swami805 on April 05, 2018, 12:45:43 AM
Good to see you back Ted,Looking forward to seeing what's next! So far batting a thousand! Sheridan
Title: Re: Failure Mode
Post by: Tiddlerbasher on April 05, 2018, 12:51:03 AM
Welcome home Ted ;)
Title: Re: Failure Mode
Post by: sdlehr on April 05, 2018, 03:11:56 AM
Ted, anyone ever tell you you're too tough on yourself? It takes one to know one.  Nice to see you back in the saddle.

Sid
Title: Re: Failure Mode
Post by: mo65 on April 05, 2018, 03:17:01 AM
   It sure is good news to hear you're back at the bench buddy. I've missed your creativity...that Seaboy looks bad to the bone!  8)
Title: Re: Failure Mode
Post by: Yogi_fish808 on April 05, 2018, 05:15:50 AM
Thanks for letting me be part of the testing uncle Ted! The design of your handle is rock solid and took quite a lot of force to twist while fighting what seemed like a large shark from the rocks. It was really comfortable to grip and the throw length was great. As long as the weather holds out this weekend I'll be taking the improved version out for another round of testing.

Aesthetically it definitely looks good on "Big Red" my hot-rodded 113HLW, let's also not forget your shift lever.
(https://i.imgur.com/hXt0UiC.jpg)
(https://i.imgur.com/5k58GeC.jpg)

Title: Re: Failure Mode
Post by: Maxed Out on April 05, 2018, 05:37:36 AM

Beautiful hlw Yogi. Thanks for your test fishing feedback and looking forward to all future reports from your fishing adventures.

  Ted

 
Title: Re: Failure Mode
Post by: Keta on April 05, 2018, 03:50:59 PM
 :)

I prefer your handle blades over my own Keta Kranks Ted.  The design and craftsmanship is first class. 

If the Seaboy projects work out I will have a black one on my 185 or the 195 (wide Seaboy 190) to give the "ugly duckling" some class.
Title: Re: Failure Mode
Post by: Fishy247 on April 05, 2018, 04:30:17 PM
Glad to see you back on here! I've been eyeballing your creations and wanting to order some up whenever you get back to production. Your handles look super comfy and the colors really make the reels they're on pop.

-Mike
Title: Re: Failure Mode
Post by: handi2 on April 05, 2018, 11:50:58 PM
Ted your products are the best to be found. Hands down..!!

If you ever need an investor im here.

Now if you started making gears that are smooth from the start I would be all in.

Keith