| Building a Wooden, Six Sided Fly Rod Case |
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| If you don't have lumber that has been surfaced, you'll need to flatten one face and one edge on a jointer. |
After running the board through a planer, cut the board to width. 1" wide strips should work for most one piece rods and 1 1/4" wide strips should work with most three section rods. |
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| Using a bandsaw or tablesaw, resaw the strips into two pieces. After cutting the strips, plane the strips to 1/4" thickness. |
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| A Lee Valley Tools Bird's Mouth Router Bit is used to mill one edge of the strip. The opposite edge of the strip is left at 90*. The angle produced by the bit forms a tight glue joint with the adjoining 90* strip edge. |
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| Feather boards are needed for a consistent cut. |
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| After applying glue to the strip edges, the rod case is wrapped with strapping tape to hold the strips in place until the glue dries. The case is trimmed to length with a miter saw. The trimmed ends are used to make tracings of the shapes of the caps on a 3/4" thick piece of wood. The end caps are trimmed to size on the bandsaw. |
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| A rabbet is made along the edge of the cap with a straight bit. A router bit with a guide bearing will also work. |
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| Leather straps are used to attach the cap to the case. The bottom cap is epoxied in place. |
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