Failure Mode

[Maxed Out]

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

[erikpowell]

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! 

All the best!

[broadway]

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

[Reel 224]

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  

[thorhammer]

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!

[farmer56]

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

[Maxed Out]

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

[TongassFisher]

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!

[redsetta]

Nice work Ted - great to have ya back.
All the best, Justin

[Shark Hunter]

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.

[Maxed Out]

 ....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

[Vintage Offshore Tackle]

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!

[Alto Mare]

Good to see you back Ted!

[Tightlines667]

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

[Jerseymic]

Welcome back Ted

Mike.