I'm building a rod for my daughter and was planning on using a colored tip top, but a size is 5.5 (2.2mm) and its slightly bigger than the rod tip factory measurement at 5 (2mm) [don't have the actual blank's measurement yet]. Should I shim it with thread? Tape? Just use a bunch of extra glue? Not that big a difference?

How much of a gap would be too much?

I don't foresee heavy use or heavy fish, just trying to make a "pretty" rod that will get her excited to use it.

Many thanks yall

I think thread would do just fine.

There's a pretty good chance that it'll fit correctly. I've had numerous rods that were the next size up tube from what the manufacturer listed.

Even if it's a little bit big, use more glue than usual, wrap it and then thread finish and you'll be fine.

Just stuff it with more glue. It’ll be fine.

Paint or permagloss can make the tip bigger. I had a rod that I applied permagloss to and the tip tip that fit snugly before wouldn't fit anymore. The 2 or 3 coat of permagloss has added some bulk to the rod.

Or use more glue like others said. Cover up with decorative tip thread wrap and epoxy.

It's a small detail item but I have found that wrapping with black A thread or D thread (depending on how oversized the top is) then gluing will help the top sit more symmetrically. Most people won't notice the difference with or without the thread, but I think most builders tend to be a little detail oriented which is why we would probably just order the right tip top, but I admittedly have done more than one underwrap + glue method on slightly oversized tip tops without any issues and the tips have turned out great.

Thanks for all the insight fellas, I'll see how snug/loose it is and be confident in the recommended solutions.

Building rods in MA, Building the community around the world

El,
If I have this situation, I simply apply layers of my standard A sized thread until the tip top is a nice fit.

By having a uniform and solid wrap or wraps of thread on the tip, the installation of the tip top will be the same as on any other rod.

This may be a particular problem for small tipped ice fishing blanks.

Because of the nature of ice fishing and often fishing in low light areas, I normally use a very bright tip wrap - like pink, orange, or some other florescent color.

As a result, if I need to bulk up the tape, I will just make my typical tip wrap of about one inch to have as many layers as necessary to have a classic fit of a tip top to the tip of the rod.

When fishing in low light areas, like a dim shanty, the flash that one sees as a fish engulfes a bait, really aids in landing more fish.