For those who are somewhat of a handyman, and not 100% particular about aesthetic and want to salvage and fix your broken expensive rod. Most Rod are salvageable/fixable.
Adding another larger diameter graphite shaft outside of the broken section will do the job to salvage most broken rod. Only the top 2 slimmest section close to the rod tip is not advisable to be fix, since too much force is constantly added to the tip of a rod.
Parts needed:
1. Some Old discarded or cheap rod having larger diameter than your original rod shaft , bought cheap as parts from Walmart or CA tire
2. Box cutter knife from dollarama or steak knife with fine teeth.
3. REAL Bamboo chopstick, free at some chinese grocery that sells cooked food
4. Fibreglass glue used by automotive or loctite steel glue or regular epoxy from CA tire
5. Clear epoxy 5 minute glue from dollarama
6. Sewing thread with right color from dollorama
7. Smooth grade sandpaper at Dollarama optional
8. Super glue- optional
9 Mini saw at Dollarama
Broken Rods are useless for most people except for fixing rod application. I always pick up broken rod wherever I found them on the ground, to be used as parts to fix future broken rods. One can also buy any cheap rod on sale from Walmart for under $10. If you have a verneer calliper to match shaft diameter, it would make life even easier. The new diameter of Shaft being used should be slightly larger and fit just snuggly outside the broken section of your rod.
1. Slowly using a box cutter knife, take off the guide on the broken section of the rod, Sand off excess glue if necessary until smooth. You will be using the same Guide again. Mark the area to ensure the guide will be aligned to the rest of the guide, the next time you placed it back on your patch rod .
2. Using the box cutter knife or a steak knife with fine teeth, saw off all visible broken fibre on the section of the damaged shaft, rotating the shaft evenly around while sawing them . You must ensure to always saw off existing broken fibre strand, since the vibration from future casting will further elongate the damage fiber on the rod shaft.
3. If you want to salvage both original broken section, you need to fit and glue 4-5 inch of bamboo chopstick placed in between the broken shaft, try to ensure the shaft are clean from any broken fiber , shaft size at this stage will not match anymore due to missing cut off section, but it does not matter, the bamboo placed inside your original broken rod section, the new outer rod patch graphite shaft sealing with fibreglass compound glue will even be stronger than your original rod, will not wobble once glue is dry . The outer rod patch can be 4-5 inches long, you will not even notice the difference in action.
Depending on the availability and complimentary section of graphite shaft for parts, sometimes, an available shaft parts can be cut and converted to one side Male and the other side female section, to fit and match snugly to your broken rod, making your rod even slightly longer.
1. Using box cutter or steak knife with smooth teeth, clean and cut off all existing lose fiber with visible broken strand, rotating the rod shaft around while sawing.
2. Find a complimentary 4 to 10â€section of a rod shaft, the diameter should fit snugly outside and inside the two broken section. Do not worry too much of the slight wobble. Try your best to find the right outer diameter that will snuggly fit your original broken rod. The fibreglass or loctite glue will do the rest, will not wobble and strong once cured.
4. Get Fiberglas compound use by automotive repair shop or use 24 hour epoxy glue or Loctite( do not use the 5 minute clear epoxy, it somewhat flexes and somewhat stretches ). You can always bring your ready -to-glue-rod to an automotive body shop and ask them to spare you a tiny amount of fibreglass compond, all you need is less than a Teaspoon full of mixed hardener and resin glue, once mixed, placed them immediately inside the rod that is being patch, It dries in 10 minutes, some small excess glue oosing outside is fine and can be sanded after 24 hours before adding the line Guide .
5. The outer shaft of a rod should always have thread wrapped and clear epoxy glue added around it for added strength. See this site for fixing rod guide.
6. To add a Guide once everything is cured, you need some sewing coloured thread and clear 5 minute epoxy from Dollarama. Mark and Align the Guide on the shaft to ensure it will be straight with the other guides. Add just a little dab of super glue to the guide to hold it in place on the shaft, ( you can also hold the guide with your fingers before rotating the thread around it, without the super glue, it will be more of a challenge) . With the right coloured needle thread, rotate around the stationary guide as evenly as possible, I am not particularly concern if the threads are 100% even , not too concern of aesthetic look, more concern of durability . Finally add the 5 minute clear epoxy glue, You have to rotate the rod while the Epoxy glue is drying, all within 5 minutes, so it does not drip and dries as even as possible. There might be some bubbles inside after it dries, but it does not bother me, it will be strong. Bubbles will disappear if heat is added, some will try to dry the epoxy glue on top of heated stove to remove bubbles, or add acetone to it before it dries. Not too easy to heat the glue without overheating the graphite shaft.
6. If the colors of the shaft being patch does not match the color of your existing rod shaft , you can always color them with spray paint ,add glossy urethane furniture paint to seal them.
I have 3 long 10ft+rod and couple of 7 foot rod that were broken and fixed. The fibreglass glue and the short replaced patch shaft is stronger than your original graphite shaft rod. By learning how to fix a broken rod once, you will never have to be too concern on accidentally breaking rod, since most rod are fixable/salvageable, or don't throw broken rod away.
Got lucky this spring, found an almost brand new but broken Pflueger 11 ft rod on a garbage bin at Hamilton harbour while Carp fishing. The top section was broken in half while the bottom section cork handle was so clean and practically new, it was like someone just took off the plastic wrap on a brand new rod , broke it while fishing, got mad and threw it at the garbage bin. Not even sure how they could have broken the rod, could be from yanking the rod when the line got snagged. The rod was rated 4-8 lb, somewhat noodlish, not easy to break that rod unless someone was being impatient and inexperience. Funny was I need a rod somewhat soft in action for my centerpin and the right rod was just waiting for me.