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FTOTY Bamboo Rod 2004


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#16 steeldrifter

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Posted 22 August 2004 - 04:25 PM

A pic of a beautiful rainbow layin next to a fine bamboo rod...does it get any better headbang.gif

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#17 Carlin

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Posted 22 August 2004 - 04:27 PM

Well... It could be laying next to a 12 pack as well. rolleyes.gif

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#18 Carlin

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Posted 22 August 2004 - 08:17 PM

I just spent some time sorting through the chopsticks. The idea is to get similarly sized ones and match them up through what will be each strip. More importantly, when assembled, each strip must be long enough for a rod section, plus a little extra for safety, so I laid them out in the order that they will glued together in the strips. You also have to be careful that, when they are all glued together, the chopsticks that originally came from the lowest part of the culm are located lower on the rod section (which is where the color coding becomes important), and that they are aligned properly - that is, with their 'butts' toward the butt of the rod section.

For example, I painted the butt section of each chopstick with a color from the rainbow. The lowest on the culm was Red then Yellow, Green, Blue, Indigo, Violet and finally black (ROY G BIV +black - I skip orange because it looks too much like red). When organizing, all I have to do is to be sure the colored end is always facing down.

Each strip on the butt section will be made up of 1 red, 1 yellow, 1 green and 2 blue chopstick. The tip strips will be 2 indigo, 1 violet and 1 black chopstick.

Finally I mark each with a number from 1-6 that corresponds to which strip they will be a part of. You can see the hash marks on each strip in the picture below (the hash mark colors are not the same as the chopstick colors, just to make things more confusing!).
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Next we'll start breaking out the tools!!

Chris

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#19 Carlin

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Posted 22 August 2004 - 09:46 PM

Before I get started on the splices, I have to sharpen the plane blades. I set the blade in a Veritas sharpening jig to an angle of around 35 degrees, and work the blade over 3-4 different grits of diamond stones.
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After the initial sharpening, I use an 8000 grit japanese waterstone preped with a Nagura stone. This will give the blade a mirror finish, and will be sharper than a razor's edge.
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It's important that the edge be clean and sharp!
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Chris

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#20 Carlin

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Posted 22 August 2004 - 09:49 PM

Once all of the blades (3 total) have been sharpened and honed, I setup the block planes. I have 2 that I use. The first is a standard flat sole, and the other has a 1" x .003" groove milled into the sole which helps keep the blade from gouging the splicing block and forms.
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The splicing block holds the chopsticks so that when they are planed flush, there is a smooth 4 degree angle to the stick.
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I start with the flat sole plane and work down until there is about .015" of the chopstick remaining above the splicing block. I then switch to the grooved-sole plane and work until it's flush with the top of the block.
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Once each of the strips have been angled, they are ready to be glued.
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I have to do this for each chopstick in the rod. Since there are 6 strips in each of the two sections, 5 chopsticks in each section of the butt and 4 in each of the tip, there is a total of 54 chopsticks and 84 splices that must be planed in this particular rod configuration. I'll be at this for a bit...

Chris

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#21 OSD

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Posted 22 August 2004 - 10:15 PM

I knew I had the right guy to help me with this section of the form. thumbsup.gif

#22 TimJ

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Posted 22 August 2004 - 10:26 PM

This is an awesome thread Carl. I had no idea how you even start to make a bamboo rod. This is very interesting and the picture of the rainbow is pretty nice to.

Tim

#23 SmallieHunter

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Posted 23 August 2004 - 09:05 AM

Man that is some crazy stuff man. I knew making one would be difficult but that is pure madness shocking.gif
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#24 artimus

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Posted 24 August 2004 - 09:47 PM

Carl,
You are a true craftsman, and this is shaping up to be BY FAR the best step-by step process of making a bamboo rod. I'll be following this thread very closely and MIGHT be asking some questions. Is there a test after you are done? tongue.gif
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#25 Carlin

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Posted 24 August 2004 - 10:14 PM

I was able to finish planing the splices on all the chopsticks this evening, so now it's time to start glueing them together to make the final strips.

I first organize them to match them up with their 'siblings' (all the 1s with the 1s, 2s with the 2s, etc.). I then sample fit and put aN alignment mark on each which helps me make sure that the splice will be even.
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Then it's a simple matter of spreading on some glue and clamping them together. The only tricky part is you need to be sure that the enamel, or top, of each of the strips is flush with the one that it is being glued to, and that the butt end of each chopstick is aligned towards the butt of the rod. This is another place where good color coding and organization pays off!
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Because I have a limited number of clamps, I have to do the glueing in 2 stages. However, since I am using Titebond III, I only have to keep things clamped for an hour or so. Later this evening I'll remove the clamps and finish with the glue up. Tomorrow we should have some nodeless strips that are ready for rough planing!!

Chris

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#26 Carlin

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Posted 24 August 2004 - 10:17 PM

Thanks Tim! Thanks Art! Please feel free to ask any questions.

Chris

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#27 MSUICEMAN

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Posted 24 August 2004 - 10:51 PM

good lord, keeping the clamp business alive and well! lol. very interesting......

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#28 Carlin

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Posted 24 August 2004 - 10:58 PM

Here is the tool list for the most recent building stage:

Adjustable mouth Block Plane(s) - Mine are Lie-Nielsen (one has a 'rodmaker's groove'), but a Record or Stanley 9 1/2 works as well. Just make sure you replace the blade with a Hock or other top-quality blade.
Sharpening stones - I use diamond stones, but anything that will sharpen a blade should work.
Veritas Jig - Holds the plane blades at a consistent angle. Invaluable for sharpening!!
Splicing Block - I picked up this one from JD Wagner, but if you are less lazy than I, you can make one yourself without much trouble.
Buttload of small Pony clamps - Some folks who make nodeless rods will bind the splices, but I find that it is much faster and easier to use clamps.

Chris

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#29 Carlin

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Posted 24 August 2004 - 11:00 PM

QUOTE
good lord, keeping the clamp business alive and well! lol.

lol.gif

Dumb me. Should have bought stock in Pony before I went to the hardware store! tongue.gif

Chris

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#30 Pujic

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Posted 25 August 2004 - 08:33 AM

That is very impressive Carl, great work!
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