I have several cork rings where the center bore is way too big - about 1/4-3/8" larger than the butt of the blank and I was wondering if it would be okay to use foam arbors to take up the difference. These rings will make up the handle and all the posts talk about small differences and using thread, twine or dry wall tape to take up the differences (small) in handles and arbors used for reel seats. With the large difference between the bore and the blank if I use tape/epoxy the weight of the epoxy becomes a concern. Additionaly I will need at least 10" of arbors for the handle and haven't found any listed that are that long.

Any suggestions on this one?

Use larger cord wound around the blank to take up the space? Get rings with smaller bore? Foam arbors don't weigh much so I don't think you would increase the weight much if you went that way?

First off why not sdave those rings for a better use Im sure there will be a build in the future darby where you can use them. Now that said if you have to use them tape or twine or thread is really for a SLIGHT difference not for big spaces. I guess you could use the foam arbor but that could get expensive. Really the only weight factor you are looking at there is the epoxy for the glue up that will soak into it and that has to be minumal. Keep in mind Darby what ever you use you will be giving up sensativity which is my mane concern in my rods whenever you put anything between your fingers and the blank never mind two things!

I have taken Flex Coat arbors and fitted them to the inside of the cork rings ( either open up the cork ring or turn down the arbor). Glue them up in sections until I get the total length I want then glue them all together. You can open up the bore of the arbors in sections or all at once to fit the blank. The arbors are probably lighter then an equal length of cork rings. I think this is one good way to do it.

I will go along with Jay on this one.

If at first you don't succeed, go fishing, then try, try again.

Depending on weight concerns and the size of the rod, I would either use FC arbors along the length of the grip, or build the handle on a piece of larger scrap blank that fits the cork, then use a couple of small arbors to mate that blank piece to the rod.