I'm cutting and adding an extension to a fiberglass fly rod and need some advice.

The extension will be a section of hollow fiberglass stock epoxied into the butt section of the blank.

My questions are:

-How snugly should the extension fit into the blank?
- How far (one, two, three inches?) should the extension slide up and into the butt section of the blank?
NOTE: Total length of the "extension" will be: 3.5" (for the reel seat) PLUS x (where x = number of inches the extension extends into the blank).

As you are going up into the grip area, no need to make it short! I'd go at least 4-5 inches, and nice and snug.....no slop.

I agree with Phil on the length. You want the insert to perfectly match the taper of the blank and fit snugly.

Use a gray scotch-brite pad to create a water-break-free surface on the extension piece, and use a good structural gel epoxy (at least 15 min. cure time).

Walt Natzke
Ripon, CA

thanks guys, i will, as you say be "going up into the grip area" on the blank and 4-5" into sounds good. The fiberglass section I have was supplied with the blank and should fit in nicely. You say to Scotch-Brite the extension piece that slides 4-5" up into the blank... then...should I put the adhesive on the inside of the blank, on the outside surface of the Scotch-Brited extension piece, or on both, before fitting it together?

Just coat the outside (male end) of the extension and then rotate it as you push it in. This will spread the epoxy evenly.
I have never "prepped" the inside of the rod blank and never had a separation.

Walt Natzke
Ripon, CA

confirmed^ verbatim

maybe just me -- but I split a piece of scrap blank , put a small piece of sandpaper in it and use that inserted into the butt to sand for a even better bond

Bill - willierods.com