Graphite Fishing Rods

The Making of the Carbon Graphite Fly Rod   

Carbon Fibers and the Main Flag and Scrim  

The main flag and scrim are made of carbon fibers that are linear and run side by side. They are in the shape of a roll. They can be produced in extremely long lengths. The makers choose the rolls with certain densities which is the number of fibers per inch across the sheet, based on the performance characteristics they are trying to get.    

Modulus is the material’s resistance to bending without breaking or permanently disfigured.  The higher the modulus; the greater the resistance you will get with less material. High modulus materials of carbon/graphite have led producers to make lighter rods while retaining stiffness.   

The carbon material comes in a roll and has been impregnated with a sticky epoxy that hasn’t been cured.  It has a removable backing that is taken off in manufacturing. The mix of carbon fibers and epoxy that hasn’t been cured in the last heating process is the pre-preg and has to be stored in a freezer prior to use.   

The pre-preg carbon is cut into shapes and patterns known as the main flag. The fibers are aligned from the tip to butt of the rod so the main purpose of the flag is to give strength along the rod’s length.  Flags are usually shaped like a triangle, but they are sometimes tailored to add to the rod’s bending and casting traits. It should wrap around the mandrel at least once to make the rod solid all the way around. The number of wraps used describes the flexion and target line weight of the rod.   

The scrim is like the main flag and is used with it, except its purpose is to give strength around the rod. This is called hoop strength.  

Manufacturing a Fly Rod 

When the proper design and combination of the main flag and scrim are figured out, the rod goes into production. The backing is taken off the main flag and it is tacked, by the scrim and a heating pad to the mandrel. When a little heat is applied to the pre-preg, it sticks to the mandrel. The scrim and main flag are both fixed along the mandrel’s length at a precise location. After this tacking is done, the mandrel would resemble a flag if it were picked up.  

The mandrel, the tacked carbon fiber, and scrim are then placed in a rolling machine, which resembles two ironing boards with one upside down. They meet and slide so that the carbon is wrapped around the material. The machine puts pressure on the mandrel and the flags to make a perfect wrap. Ferrules are reinforced also when the blank is rolled, by the use of smaller flags that are simultaneously rolled with the rod on the table.  

When the rolling is finished, the rods go into a machine that wraps clear cellophane tape over the whole rolled carbon tube that is on the mandrel. This wrap is very resistant to heat and has to be put on with the right level of pressure. The mandrel is then placed in an oven where it expands a little. The wrap shrinks as needed and assists in compacting the carbon main flag and the scrim into a tapered, solid tube. The oven is usually set at approximately 250 degrees, but this varies depending on the kind of epoxy or resin that the carbon fibers contain. This process, curing, brings the rod to its final shape - a solid carbon tube known as a blank.  

A special machine is used next to part the mandrel from the blank. The blank is sanded to make it smooth prior to painting and the clear, coat finish application that gives the blank the desired color.  

The blanks then have to be finished before they can be put together as fly rods. They are trimmed to the correct length and load characteristics, and the pieces of blank are fitted together to make sure that the correct level of engagement has been achieved in each of the ferrules. After this is done, the rod is placed in an epoxy mixture that is an essential part of the rod and is instrumental in protecting the rod from chips. This dipping usually needs an additional curing before it is finished.  

The blanks are ready to be assembled. Reel seats and cork grips are glued to the blank. Along the rod’s length, guides are spaced, and then they are manually wrapped into place. The wraps have special coatings to prevent slipping and corrosion.  

Lastly, before the finished rod is put on the market, they are usually tested for things such as, load characteristics and flex profiles.