I've built several fly rods over the years, but am building my first spinning rod (Rainshadow IS, 5.5' 2 piece ultralight). I had just finished wrapping the guides (fuji single foot), and had run the line through the guides to check my spacing. Under moderate load, say what a 12 inch smallmouth would do, the tip broke right at the upper end of the wrap on the second guide, about 11 inches from the tip. Except for a few graphite fibers sticking out on the opposite side from the guide (along the spline), it's a clean break. This was the first time any load had been put on the blank.

I had a fly rod break like that once, but it was when I put too tight a bend in the tip while pulling the leader through. In this case, there was nowhere close to that much strain on the blank. Could I have caused this with some kind of wrapping mistake, etc? I used A thread, and I'm confident that I hadn't nicked the blank or otherwise damaged it there. I'm making this for my son's birthday next month, so time is getting a little tight and I'd prefer not to make the same mistake again. Thanks!

Wayne Chubb
Fair Oaks, CA

Possible too much tension on the thread?

If the rod had not been used, and therefore had no chance to be damaged in an on the water accident, and you are sure you didn't use excessive tension, the in all likelyhood the blank was either defective or had been damaged in shipping. It's always a good idea to safely stress test any new blank and inspect it closely for flaws before you begin wrapping it.

I strongly suspect that if you return it to the folks at Batson Enterprises they'll look after you. It is possible you may be able to obtain a new tip which would save you from having to rebuild the butt section.

...................

I'm still working out bugs in my new rod wrapper, and the thread tension system I came up with is one of the buggiest - so, yeah, thread tension could well be it. As always, great quick responses - it's a great resource you've put together, Tom. Thanks.

Wayne

A similar thing happened to me not too long ago. I was building a 10-wt fly rod, and through all the testing -- finding the spine, static distribution, test casting, etc. -- the blank held up fine. I finally got the rod completely finished -- it was a beauty, at least to my biased eyes -- and even though it was January, I put a reel on, and even a leader, and trudged out the back door to try it out.

The fun lasted about three minutes. I made a few casts, and reached down and gently put the tip-top between my thumb and forefinger. Just like that - snap - the blank broke between the tip-top and the first guide. I almost cried.

I don't know much about the technical aspects of blank construction, and while I acknowledge that it might have been something I did, I nevertheless think that the blank was defective, and had a weak point that was going to break sooner or later. When I looked back at the building process, I couldn't see anything that I did that would compromise the blank to the point of breaking.

And it happens, I guess; manufacture 10,000 units of anything, and the law of averages says that at least a few are going to have problems. Fortunately, I bought the blank from a good purveyor (and board sponsor, Mudhole), and while they couldn't replace it (it was a no-longer-manufactured closeout, and mine was the last one they had), they did give me a credit.

Hey Wayne,
I live close by in So. Sac. tried to email you but your address is hidden.
email me RCAdams1957@msn.com
or drop me a line 916-422-5531
I'd be glad to help if I can.

Good luck with the rod

Raymond Adams
Eventually, all things merge, and a river runs through it..

All the rod MFG's state/concurr that if a blank truely has a MFG material defect, 90% of the time it will show up during the first few uses. Barring abuse... i.e. a nick, highsticking, or the thread tension was too great. It sounds like it was a hidden defect and replace able, too bad you'll have to send in the butt section because they will have to ferrule fit a new tip section to that exact butt section which will save you some work but not postage

I agree with Tom, the Baston company will work with you. Give them a call it is toll free 1-877-875-2381. You might check for a burr on the guid foot
Good Wraps Bob

I recently bought a Rainshadow 5.5' 2 piece ultralight that I wanted to build as a trout rod. When I received it, I put it under a light test load and it too broke about a foot from the tip. I reported the damage and the fine folks at Batson's replaced it without a problem. I too recommend that you contact them. They stand behind their products.

Rich Matranga
Folsom, California