alan tani @ fishing reel repair rebuild tutorial Handle fitting for a BeastMaster 4/0
Reel Repair by Alan Tani
November 29, 2020, 02:54:39 AM *
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Author Topic: Handle fitting for a BeastMaster 4/0  (Read 765 times)
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Auckland, New Zealand

« on: September 12, 2020, 09:22:39 PM »

Hi all,
Thanks again to Ted (Maxed Out) for so generously parting with a couple of 6/0 Tani/Kolekar handles.
They're destined for my three Shimano BeastMasters - 4/0, 30/50 and 50/80.
One of the myriad issues I found while test fitting the 4/0 was that the press-fit handle shaft is 7mm, while the replacement handle screw is imperial and a fraction under 5mm.
Once drilled out, it was apparent that I'd need to sleeve the hole down to 5mm, so the new handle would fit tight in the blade.
The gap measured 7mm OD, 5mm ID and 4mm width.
I tried a wide array of different solutions, including turning down stainless washers and split washers, but nothing was working quite right.
I happened to test the measurements on an old Shimano Baitrunner handle shaft, and sure enough the ID and OD were spot on.
So I cut off the handle, drilled out the spindle and cut the shaft to three 4mm sleeves for the three reels:

You can see here the BeastMaster blade with the 7mm hole, sleeved down to 5mm:

Then with the imperial handle screw, about as snug as I was able to achieve:

The new handle - this one a gift from Sal from a year or two back:

Turns out the handle screw was too big to clear the lever drag, so after much grinding and customisation, here's the finished article:

Righto, hope you're all well and making the best of the circumstances.
Cheers, Justin

Fortitudine vincimus - By endurance we conquer
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« Reply #1 on: September 12, 2020, 11:02:23 PM »

Good job Justin, should work good, cheers Don.

Don, or donnyboat
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« Reply #2 on: September 13, 2020, 01:48:45 AM »

Good improvisation Justin, thanks for sharing some of your handiwork.


It can't be too difficult - a lot of people do it.
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