I purchased model HKS-4 a while ago and I'm about to start building a rod that I'd like to use this handle on. Still being a Newbie, I'm kind of confused what is the best way to install the end cap plug. I've seen one video on Get Bit where the end cap actually fits into the hollow of the rod. That's not going to work in this case, the plug is larger than the rod.

I have a couple of thoughts, first one is to ream the but portion of the cork handle (about 3/4") so it'll be large enough to accept the plug, then epoxy it in.

The second would be to ream the entire length of the but handle, making it oversized, and then create arbors and use lots of epoxy to fill the voids.

I know there has to be a better solution out there but I haven't found it yet.

Any hints to the best way to tackle this problem?

Thanks!

Dave

Dave,
[www.getbitoutdoors.com]

So, I assume that you are looking at finishing the butt section of the rear grip? I take it that the rear grip has a hole in the butt section of the grip? Then, there is a plug that comes with the grip to plug the open hole?

If that is the case, I spin the plug and reduce the size of the plug so that I create a tapered plug that will fit into the open end of the rear grip. Then, I sand the end of the grip so that it is at 90 degrees to the rest of the grip and smooth.

When you glue the grip onto the rod grip, you extend the rear grip the 3/8th of an inch or so past the end of the rod blank so that the rod blank is not part of the problem when you put the plug in the rear grip.

If my understanding of the problem is not correct, can you snap a couple of pictures and post them in the picture section to better indicate the problem?

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This is the setup that I use when building rods with solid cork grips. I bore the grip to be a size that fits nicely onto the rod blank. Then, the hole in the end of the grip is about the size of the rod blank. I use a plug cutter to cut plugs from cork rings and then shape the plug to be tapered and to nicely fit into the hole in the end of the grip. After the glue sets, I slip the grip - placed in paper towels to keep the grip clean - into the jaws of the cross vise that is mounted next to the face of my disk sander. Then, using the cross vise to advance the end of the grip up to and slightly further of the face of the spinning sanding disk. Then, I use the other cross vise control to advance the grip across the face of the disk to provide a perfectly smooth rear grip that is at 90 degrees to the rest of the grip.

[www.rodbuilding.org]

So, I've used a bunch of those St Croix handles. They are great, btw. Too bad they are gone, especially the fly handles. Don't make this harder than you need to. Insert the plug to the greatest depth it will go. Then ream the grip so that that depth will protrude beyond the blank. Assemble the grip, then Epoxy in the plug. After it's dry, cut off the excess, sand down (a belt sander makes this a 30 second job), until flush and move on. I usually cut off about 1/2 of the plug. Don't sweat this, it's easy.

Thanks for the replies, I used Drew's method and it worked out fine.

Have a great day!

Dave