I thought I'd try arboring by pouring 8# expanding foam directly into the reel seat. I've successfully completed three of them and figured I'd better ask for your opinions about it. This is what I've done so far... The grips are EVA and I turned the tenon to fit the reel seat snugly. I then sliced a 1/4" piece of the tenon off to act as a fitting to center the front end of the reel seat. I glued up the EVA to the blank. I put enough 5 min epoxy on the grips tenon to get a good seal and slid the reel seat into place with the 1/4" piece tucked in the front end to keep the seat centered on the blank. Once the 5 min epoxy was set up I pulled the 1/4" piece out and was ready to pour the foam. I had already calculated the volume required, allowing for expansion, and carefully mixed up the foam and poured it directly into the reel seat and capped the front with the 1/4" piece tucked inside. The 1/4" piece was snug enough to halt the foam from expanding too much (so far). I peeled off the 1/4" piece on each of the three rods and the foam had expanded right up to them and stopped there.

Pros: real easy, fast, perfect fit
Cons: if I do mix too much and the 1/4" pieces don't stop the expansion I'll have a real mess. Full length arbor where a couple small pieces should be all that's necessary.

Opinions?

Yes, if you don't figure exactly, you will have a mess that you cannot believe. I'm not sure the pre-formed Flex Coat type arbors aren't less expensive and less risky than this operation. But, I do applaud your efforts and congratulate you on this most successful experiment.

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Reading this, the thought just crossed my mind: What about using that insulation foam that is used in houses to stop air infiltration? It's a push the button and no measuring required. As a appraiser, I've seen that stuff on the even on the outside of houses that's been in place for years in all of the northern Michigan weather and it is still hard and firm.

Just a thought.