I build fly rods using old school craftsman methods while utilizing modern high quality components. The process begins with splitting the Tonkin cane into approximately 1/4 inch strips. These strips are then rough planed to a uniform width using a hand plane. Next the nodes are filed flat and the strips straightened though a process of heating and straightening.
My rods are made up of six identical strips which are planed on a 60 degree angle so when glued together they form a hexagon shaped rod. To get the initial 60 degree angle I run the strips through a surface planner on a custom table which holds the strip at 60 degrees. After several passes on alternating sides I have eighteen consistent strips. These strips are then heat treated in a warm oven which removes moisture and straightens the strips.
This is the point where the rod starts to take shape and becomes personalized to the angler. The rod sections are hand planed on a steel planning form which allows you to taper the rod to various specifications. The rod taper is what controls how the rod will perform and feel to the angler. I use both classic and modern tapers specific to each customers requirements.
Once the planing is complete for both the butt and tip sections they are glued up and bound to apply equal pressure while the glue dries. The finished blanks are then inspected and sanded. The ferrules are fitted and applied using the same epoxy used to attach the head of a golf club to the shaft.
The final stages include; turning the cork grip and reel seat, wrapping the guides in silk thread and finishing the rod with three coats of marine grade polyurethane.