Reel Repair by Alan Tani

Hey guys!

I spoke to Alan C. a little while ago and was telling him how I really like his 5:1 Newell gears he made and put them in my Jigmaster 505hs, they are here http://alantani.com/index.php?topic=11827.0 . He then asked me to post about them here if I could. I have been very busy as there have been some personal things going on lately, however I have found the time and would like to share how great these gears are!!!

Here are the gears! 416 heat treated SS 5:1 gears (actually 4.8:1 as they were modeled after the original Newell gears)



As the title of this thread says, I will be upgrading a Jigmaster 506HS. When Alan C. talked to me about it, I got the idea to make an entire build out of this. I sold off my 505 and looked for a solid 506 to build, as I wanted the side plate to actually say 506hs on it. I quickly found a VERY nice 506hs in 9/10 condition.

Here it is!





Its a beautiful reel and has the full Newell conversion! I got this bad boy for $75 shipped to my door, which I think is a solid price.

Also, upon taking it apart I noticed that it had been service and well taken care off! Even the screws had at least oil on them!



Okay, here are the upgrades that will be going into this build!



I started with the upgrades going left side to right side. I took apart the left side plate and found it in GREAT condition! So I just cleaned the plate up and then Swapped the bearings with Boca ABEC 7 Orange Seals. I decided alot about which oil to use and settled on TSI 321, to protect the SS part of the bearing and it works as a great lube even though it wont bond to the ceramic balls.




Now even though this reel came with the Newell bars, I could not resist the SS bars from Alan C. I ordered some up and swapped them out, but leaving the Newell reel stand (as it is much better than the stock one)




As a few of you know, I LOVE SS screws, so I swapped out the side plate screws with SS screws. They sit a little higher but I think they look good and are a great pair with the SS bars.




Now on to the right side plate and the fun stuff!! I swapped out as much of the guts to SS as possible! Here is a pic of everything that is getting swapped out.



The SS gear sleeve is ground down to utilize a Keyed SS washer for a better surface for the Delrin or CF washer (whatever your preference is) to operate on. I used a 0.50 mm SS 5-60 washer from Bryan and then used the 0.020 PFTE Derin sheet and cut it to the same size as the SS washer.




Here are some pics show the old brass gear next to Alan C's Newell SS gears, as this is what the build is mainly about.





As you can see the gears look VERY similar and the operation is very smooth! A 5+1 one stack the Bryan sells for the Jigmaster will fit in here nicely and then I placed the acetal washer that Sal has been suggesting.



The same Eccentric jack and yoke for the 500 will fit in the 506, so I used Alan C's yoke and jack as they are heat treated SS.



Only things is that the OD of the spacer is to wide for the plate. So I just took a dremel and slightly opened the OD of the plate to fit the spacer. Here is the plate after I shaved a little off.



Now before putting it all back together I swapped the bridge screws for SS ones. I had to grind the threads down a little for the yoke bridges, but now they fit directly in with no issues.




Now a quick polish of the pinion and spool shaft as I will be using this reel for casting.




Once the reel was all together I noticed a few things. The spacer was wayyyyy to tall and the acetal washer was a little to soft for this setup! I went through ALL the sizes of spacers the Alan C offers and all were to Tall except the 10.5, which fit nicely! But I did swap the washer for Bryan's spring washer. I placed a Delrin washer under it though.




All back together and ready to take on anything I throw its way. I will be using this for yoyoing and throwing surface irons to schoolies.





The gears are great for this reel and really make it a MUCH stronger reel! I pushed easy 20lb drag from this reel and have great freespool! Im excited to get this on the water.

Wonderful work.  That really turned out nice!  Great attention to detail!

     Very nice . I like your choice of handle. It goes nice with the reel and looks like it will do the job well.

Great job - that's a beauty!

  nice 506

Beautiful work Jason. When you mention that the Delrin belleville didn't fit, could you be more specific?, did it hit the side plate or did you have an issue with the star? You've also mentioned too soft, I'm sure you mean to springy, that would be a good thing. The acetal itself is very strong.
Also, could I have the part # of the ss bridge screws, I want to help look around and see if I could find some as the original.

I've been telling Alan to forget about the 5:1 and go as the original from the beginning, I had no idea those were 4.8:1,  I would have grabbed a set or two...oh well.
The cross bars look amazing, those will last forever, to me its one of the best upgrade we did here. I'm glad you're sticking with the Delrin.
You did good buddy, enjoy that beauty.

Sal

Quote from: Max Doubt on February 15, 2015, 07:37:11 AM
    Very nice . I like your choice of handle. It goes nice with the reel and looks like it will do the job well.

x 2 - Looks good. It looks like you started with a 24-66 handle but what is the black arm on the finished reel?  
Michael

Two thumbs up and a gold star!

Nice upgrades. Very solid work.

That's a weapon. Very very nice.
I would really like to do something similar to one of these.

Your new pinion has a larger hole for the rectangularish engagement portion of the spool shaft. The original gear has a smaller hole as the 505/506 spool shaft where this engagement portion clicks in. Do you think that this uneven pressure on the engagement portion of the shaft and on the new gears will damage the shaft or gears over time??

Great job

Nice reel you got there.

You need to end your drag stack with a keyed washer.  Under high tension of the drag, the star may loosen as line peels off the reel.

In your case, I it sounds like your spacer is just too tall.  If that is the case, I would run your reel without a tension washer and put back the keyed washer on the top of the drag stack.  I would hate for you to loose a fish of a lifetime by the drags backing out when the fish is peeling line off the reel.

outstanding work

I heard you guys talk about it before, personally, I would never go without a tension spring...just my 2 cents