Not really a "hack" per se, but just a way to emulate an inletting tool set I have but isn't on the market any longer (as far as I can tell). I am building a cork fly rod handle and have a reel seat with a recessed hood OD that I don't already have a cutting tool for, and since I can't find the inletting tools on the market I had to use this simple work-around. All you need is 1) a lathe (or equivalent), 2) a forstner bit (sized to the hood OD), and 3) a length of turning mandrel to use as a "pilot". For the "pilot", I just cut off about 8" of a turning mandrel I already had which was slightly bent, hence useless for turning (obviously, you will be using the unbent end). So this "pilot" will have one end that is flat (the end you cut), and one end that is tapered on the inside. I haven't been able to post pictures here or I would post photos to show the process (I follow the instructions but...), so let me try to explain in words alone. First you put your forstner bit into the lathe and secure it. Then you insert the mandrel into your cork handle, with the tapered end of the mandrel (i.e. opposite of the cut end) sticking out of the butt-end of the cork handle about a half of an inch. Turn on the lathe and carefully align the tapered end of the mandrel with the point on the forstner bit. Then, holding the cork handle perfectly horizontal, gently push on the handle so that it SLOWLY slides over the forstner bit until you have achieved the necessary depth. I always eyeball it, but a piece of tape or marked line on the forstner bit can be a helpful way to assure proper depth. As always, use eye protection and be VERY careful when getting your hands this close to the cutting bit. One thing I always do beforehand (whether with my hack or with the commercial tool) is to make sure that the handle slides very easily on the pilot... the last thing you need is to have the cork grip stick and move in a jerky fashion as you are pushing it toward the forstner bit. If you don't have a lathe, you could always secure a drill motor into a vice and make it work... but then again, if you don't have a lathe you probably don't have an extra turning mandrel laying around. They cost less than $15 at Mud Hole and elsewhere. Hope that helps those of you who are fairly new to turning cork handles and haven't found an inletting tool you like. For this "hack", all you need are a few sizes of forstner bits (available online or at all hardware stores) and a turning mandrel.

Check the RodMaker issue before last for a very easy way to inlet for a seat hood. Doesn't require a lathe and only a spade bit sharpened in reverse.

And then there is the "old School" method of assembling the seat on a "rod" of some kind, about 2 ft long.
Can be a scrap blank, wood dowel, anything that is fairly stiff and will let the cork slide down snugly to the reel seat.
Make sure they are both fairly centered.
Then, make a light pencil mark ( sharpened White wax marker is best) around the hood.
Then, "carefully" work down with a Dremel style tool, one that has variable speed is best.
With a careful and a light touch, the recess can be made.
Hope this helps with another alternative to special tools.

Best wishes,
Ron Schneider
Schneider's Rod Shop
Mountain Home, Arkansas
[www.schneidersrods.com]
mtnron40@yahoo.com
870-424-3381

Thanks Mike. I will check that out. I subscribed a few years ago and just didn't see much related to fly rods, which is all I build, so I didn't renew.

And thanks Ron. I love my Dremel tool, but you have a steadier hand than I do! Or maybe just more patience. But since most people don't want to invest in a lathe just to build one or two handles, it's always nice to see alternatives. However, for anyone who is serious about building more than a few (I only build for friends and family, but I've built well over a hundred fly rods by now), I really encourage buying an entry-level lathe. I use a WEN and am very happy with it.



Edited 1 time(s). Last edit at 04/04/2024 09:03PM by David Polcyn.

It's funny... others say the magazine is all about fly rods. I guess that means I'm keeping a good mix.

........

I have been using my drill press like the video on the Flex Coat website.
[www.youtube.com]