The Manufacturing of Fly Rods & Reels

Manufacturing Fly Rods & Fly Reels

For those of you that are not familiar with terms used to discribe fly rods & reels and how these terms relate to the manufactured product, the following information will give you a general idea of how fly fishing equipment is manufactured and what it is manufactured from.

Fly Rod Manufacturing:


Carbon fibre high-tech fly rods are manufactured in several rod actions, slow - medium - medium fast - fast. Modern fly rods are almost always built out of carbon graphite or glass fibre.

Fly rods manufactured from graphite consist of graphite fibres are laid down in sophisticated patterns to keep the rod from flattening when flexed. The rod tapers from one end to the other and the degree of taper determines how much of the rod flexes when loaded while casting or stressed when a fish is on. The amount of flex a rod has determines the action of the rod.
"Action" refers to the responsiveness of the rod to bending force or curve, and the speed at with which the rod returns to its neutral ( normal ) position. )
  • Fast Action rods flex most in the tip section.
  • Slower action rods flex from the tip to the butt section of the rod.
  • The more glass used in the manufacturing of a rod, the slower the action.
  • Bamboo ( cane ) rods are considered a slow action rod due to the characteristics of the bamboo.

    Fly Reel Manufacturing:

    Precision Machined: Machining is not just one process; it is a group of processes. There are many kinds of machining operations, each of which is capable of generating a certain part geometry and surface texture. An unfinished workpiece requiring machining will need to have some material cut away to create a finished product. Machining requires attention to many details for a workpiece to meet the specifications set out in the engineering drawings or blueprints.

    Die cast construction: Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most fly reel die castings are made from a non-ferrous metal such as aluminium. Depending on the type of metal being cast, a hot- or cold-chamber machine is used. This brings about elements which are extremely resilient.

    Fly Reel Drag System:The fly rod it self provides some control of the fly line coming off the reel when a fish is on. However some form of mechanial drag system usually is needed inorder for the flyfisher to have the control needed to properly fight and land a fish. The drag system is a mechanical means of applying controlled pressure to the turning spool of the fly reel, acting as a brake against it. It can be a simple flat spring pressing against the edge of the spool, or a complicated arrangement of leather, teflon or rulon discs which provide the drag system on a reel.

    Rulon disc drag system : Rulon is a high-performance plastic recognized for its chemical inertness, massive amount of functioning temperatures, abrasion resistance in addition to low coefficient of friction. Rulon is employed in automotive engine piston rings as well as bearings, a terrific product for a fly rod drag system!

    Manufacturing vs Price:
  • Carbon fly rods commonly are priced higher that glass rods.
  • Bamboo rods will be much higher in price than carbon or glass.
  • Hand Crafted rods & reels will cost much more that the typical production line type equipment.
  • Machined reels will cost more than die-cast reels
  • The type of drag system on a reel will also determine the price.




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