alan tani @ alantani.com fishing reel repair rebuild tutorial cutting custom drag washers from penn ht-100 stock
Reel Repair by Alan Tani
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Author Topic: cutting custom drag washers from penn ht-100 stock  (Read 33261 times)
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alantani
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« on: December 25, 2008, 12:19:06 PM »

i have a box filled with the 25 or so different smaller ht-100 drag washers that penn makes. 



i am frequently faced with a situation where stock penn ht-100 or carbontex drag washers will not fit.  if the penn washers are thin enough to fit, then i still often have to deal with the outside dimensions.  what i can do is find a washer with the proper inside diameter and thickness.  then it's just a matter of cutting down the outside diameter to fit.  what i'll do is find a shaft of some sort that will fit the inside hole.  i will used a drill bit or, in this case, a deep socket, to serve as an arbor.



slide the drag washers over the socket.

now you have to hobble something together to hole the drag washers in place and keep them centered.  an old bench grinder will make quick work of this.  my bench grinder is on a rolling stand.  it goes out in the drive way, then i point a fan at it to blow away all of the carbon dust.  this is not the kind of stuff that you want to inhale. 



hold the stack of drag washers against the grinding wheel and a slight angle.  the drag washers will spin like crazy, and get ground down at the same time.  particles of carbon (and fiberglass, in the case of the thicker penn drag washer), will fly everywhere if not for the fan.  like i said, don't inhale this.





« Last Edit: December 25, 2008, 12:19:38 PM by alantani » Logged

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« Reply #1 on: January 05, 2009, 08:33:25 AM »

The master assasin wrote:
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Alan..whats the difference in material between these penn ht 100 washers and the carbontex ones?

there are two types of penn ht-100 washers, thick and thin. the thin ones are a simple weave of pure carbon fiber and these are flexible. the thick ht-100's have a layer of fiberglass between two thin sheets of carbon fiber and are not flexible at all. thick and thin. that's it. if you look at the box of washers, you will note that some have a white core while other's do not. my list of penn drag washer dimensions tells you which is which.http://alantani.com/index.php?topic=21.0

cabontex drag washers are a more expensive and more complicated weave. some are ultra thin, some are ultra thick. i know nothing about the weaving process behind it, but i do know that the material is the same, it's the weaving process that determines the price. there is absolutely no way to get a stack of five penn drag washers into a daiwa saltist or saltiga because they are too thick, but you can easily fit a set of thin carbontex washer in.

in terms of performance, you will not be able to tell the difference in smoothness. thinner drag washers, however, may allow for a stack of 5 drag washers instead of three. that may mean 25 pounds of drag instead of 15, and that could be a serious advantage. that's why i'm such a grateful customer of carbontex at smoothdrag.com!
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« Reply #2 on: January 05, 2009, 08:40:48 AM »

Quote from: White Bear;68313
Alan, Do you fabricate a gauge, to determine when you have the correct size?

nothing that fancy.  i just grind it down little by little, then check to see if they will fit inside the gear.  that's really my only gauge. the fit does not have to be exact.  if it wobbles around inside a little, there's no problem.  alan
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« Reply #3 on: April 03, 2009, 07:37:11 AM »

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hi alan, first of all, can't seems to be able to match what ive got to your list.  i have all the dimensions for what i need and got no where.

what you can do is cut down the washers that are too wide.  http://alantani.com/index.php?topic=175.0  you can also pick a washer that is large enough in the center and has a small enough outer diamter to fit.  if it wobbles around a little, or even alot, it honestly does not matter.  as long as the drag washer is trapped inside the spool, it will work.  the most common problem is that the penn drag washers are too thick.  then you have to go with carbontex.  the carbontex drag washer that i find myself using most commonly is the one for the ambassader 4000/5000/6000 series.  it's dimensions are 8.20 x 22.92 x 0.47 mm.  to make up some height (if needed), you can double up just one of them and you should be set. 

stradic 8000fh 3 washer x 2 spools of 5.10mm x 25.00mm x 0.98mm - use the six of the #6-309's

stradic 1000fh only 2 washer at 4.5mm x 19.50mm x 1.0mm - hand cut a pair of #6-7000's

twinpower 2500fb needs 6 of 5.4mm x 21.00mm x 1.2mm - use the #6-60's

sustain 4000fd needs 6 of 5.4mm x 21.00mm x 1.6mm - use the #6-7000's

certate 2500r custom needs 9 (3 spools) of 8mm x 26.00mm x 0.8mm - use the #6-4200

certate 3500hd needs 3 of 9.2mm x 26.00mm x 0.75mm - use the #6-4200

tierra 2000 needs 6 of 8.6mm x 22.00mm x 1.0mm - use the #6-60

« Last Edit: April 03, 2009, 07:59:13 AM by alantani » Logged

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« Reply #4 on: June 14, 2011, 07:22:34 AM »

Hi Alan,
Sorry for bring up an old post.

I am just trying to get a better understanding.
Am I right that Keyed means internal of the drag is either hexagon or square? Or does it means the external have a ear?

I am looking for a piece of HT100 washer to make at least 3 pieces of smaller washer by the size of 17mm(OD)
Would "#56-440 ($1.50) / 8.88 x keyed 30.93 / 0.90 / 440 ss" be suitable?

Many thanks!

Regards,
Billy Cheong
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Bryan Young
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« Reply #5 on: June 14, 2011, 08:08:58 AM »

Hi Billy,

Alan is on vacation, so I'm jumping in. 

Keyed is referring to either ears, tabs or corners on the outside diameter of the drag washer.  This "key" is not measured, just noted, and is in addition to the OD of the washer.

Internal Hex configuration is noted as Hex in the drag washer description.  See http://alantani.com/index.php?topic=21.0

Hope this helps.

Bryan
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Cheesy I talk with every part I send out and each reel I repair so that they perform at the top of their game. Cheesy
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« Reply #6 on: June 14, 2011, 06:31:37 PM »

Hi Bryan,
Thanks for jumping in.
I noticed Alan mentioned "here is a list of the 25 smaller drag ht-100 drag washers that penn makes."
Did he mean that there are bigger drag ht-100 that penn makes?

I need one that can allow me to cut out at least 3 pieces of 17mm OD washers but it seems that even the biggest one listed is too small for my application.

Appreciate your help.
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« Reply #7 on: June 14, 2011, 08:43:58 PM »

Billy, the washers listed notes ID first, then OD, then thickness.  Is it possible that

       #6-155 ($0.65) / 10.65 x 17.92 x 0.93 / 155 beachmaster

will suit your needs, and ground down a bit?
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Cheesy I talk with every part I send out and each reel I repair so that they perform at the top of their game. Cheesy
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« Reply #8 on: June 14, 2011, 10:49:06 PM »

Hi Bryan,
Appreciate your reply.
I do not have the tools to trim the external efficiently. However, I can use dremel tool to make a nice small washer if the internal "hole" is less than 1mm. What I did last time for my Tica Cetus' drag washer is to cut out a piece of drag pad, punch a hole in the centre and slowly grind it into a nice round washer using sand paper.

This time, I am looking for a bigger washer so I can produce 3 pieces of 17mm washer out from it.

Many thanks for your help Smiley
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Alto Mare
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« Reply #9 on: July 01, 2011, 03:03:45 AM »

Hi Bryan,
Appreciate your reply.
I do not have the tools to trim the external efficiently.

Try scissers, mark it first with a metal washer of size.
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« Reply #10 on: July 12, 2011, 11:20:30 PM »

i can get corbotex material in a sheet form approx 20cmx 15cm and 1.06mm thick if that helps you or anybody for that matter.
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Bryan Young
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« Reply #11 on: July 12, 2011, 11:40:55 PM »

Hi Bryan,
Appreciate your reply.
I do not have the tools to trim the external efficiently. However, I can use dremel tool to make a nice small washer if the internal "hole" is less than 1mm. What I did last time for my Tica Cetus' drag washer is to cut out a piece of drag pad, punch a hole in the centre and slowly grind it into a nice round washer using sand paper.

This time, I am looking for a bigger washer so I can produce 3 pieces of 17mm washer out from it.

Many thanks for your help Smiley

Would this work?  #56-710 ($0.90) / 7.92 x 14.68 x 1.22

It's a little smaller and when you look at the outer edges differences, you are only talking about 1.25 mm or so.
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Cheesy I talk with every part I send out and each reel I repair so that they perform at the top of their game. Cheesy
Alto Mare
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« Reply #12 on: January 28, 2013, 06:22:46 PM »

I run out of some drags, didn't want to wait to get some, so decided to cut my own. I remembered that I had some leather punches, that I purchased on ebay a while back for $15 for the set.... not bad.




A couple of hits with the hammer on a block of wood and you're in business.
I'm doing it in the house, no dust.
Sal
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« Reply #13 on: January 28, 2013, 07:17:28 PM »

just read an article on the punches and a smear of grease will make them cut cleanly through c/f.
what sort of grease you may well ask,
well there,s, and, also, dont forget,and what about, and that doesnt cover them all Roll Eyes
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Alto Mare
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« Reply #14 on: January 28, 2013, 08:14:45 PM »

 Grin Grin
Do you remember the sheets? compliments of Wallace,  I believe you know that stud Wink

Good tip on the grease, maybe I'll use Cal's and kill two birds with one stone. Grin

I still have a couple of sheets, keeping them for the larger washers.

Thanks again buddy.
Sal
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