= After the rod taper is selected, appropriate bamboo is selected.
Some bamboo that is suitable for a 6ft 3 weight may not be for a 7ft
5 weight. Because bamboo is a natural material flaws must be evaluated
and in some cases an entire stick of bamboo will be rejected.
= The bamboo is split into strips approximately 1/4 inch wide.
= The "stagger" is created. Tonkin Bamboo grows in sections.
Each section is about 14 to 20 inches long. A node or nodal dam caps
the end of each section. In nature, these nodal dams add strength
to the bamboo plant, allowing it to grow to remarkable heights.
In rod building, these nodes are weak spots and are staggered to balance
casting stress. There are several ways to stager the nodes.
= The strips are straightened to remove the natural curves and kinks
in bamboo.
= Strips are then milled to the original bevel. In cross section
this bevel will be an equilateral triangle. There is
no taper in the strips. That will come at a later step.
= The individual strips are inspected and any strips with problems that
can't be overcome are rejected.
= The strips are bound together into what will become a section.
= The section is "heat treated." The bamboo is basically cooked
at temperatures of over 300 degrees F. for a short period.
= The individual strips are planed to the final dimensions. Each
strip is inspected through out this critical process.
= The strips are joined using 4 or five pieces of masking tape. The
taped section is inspected for problems. The masking tape is slit
open between two strips and glue is applied. The strips are once again
bound into a section. The section has any kinks or bends removed
before the glue sets.
= The section is set aside to allow the glue to cure for 24 to 48 hours
= The section is again inspected and heat is used to take any remaining
bends out of the bamboo.
= The sections receive a protective coating of varnish, polypropylene,
tong oil, or other suitable finish. (Brushing, wiping, spraying,
or dipping may be used to do this.) The rod is set aside to
allow the finish to dry. This process may be repeated as many as 4 times.
= The section is cut to final length and hardware (tiptop, ferrules)
is added. At the end of this step the sections
of the rod will be identical lengths.
= The reel seat and handle are glued in place.
= Guides are taped to the rod. The rod is "tuned" by adjusting
the placement of the guides. The guides are wrapped.
The wrappings are coated with a protective coating.
= The rod is approved by fish.
= The rod is placed in it's bag and tube and is ready to be fished.
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