Ferrule Plugs

 

Happy Valentines Day 2016!!!  Today I finished a couple of ferrule plugs. First ones I made on the lathe out of hardwood. These are Oak. The darker one I dipped in some stain then both of them have been brushed with several coats of Helmsman Spar Urethane. I know my quality will improve over time, but these give the new mounted ferrules some protection now....

Newly 'minted' hardwood ferrule plugs. Right one has been stained. Both brushed with Spar Urethane.

Bamboo ferrule plug on left I made some time ago. It has no cork for the retainer.

Another older non-cork bamboo ferrule plug.

As the new two Garrison 204e fly rod wraps dry before final dipping, I decided to learn how to make ferrule plugs. These ornate (or not...) ferrule plugs protect the inside of the female ferrule while the fly rod is not being used and taken down and/or stored in a rod bag or rod tube. These little pieces keep dirt and dust out of the female ferrule that would otherwise case unnecessary wear on the female/male ferrule connection. I bought a couple of the CSE (Classic Sporting Enterprises) ferrule plug kits from Jeff Wagner to try them out. These are quite nice and are turned from aluminum and supplied the appropriate size cork in 5 different sizes.
I bought some aluminum rod to try to turn some of these in a design not decided on as yet. A small hole will be drilled on the base end and a brass 1/16'' solid rod will be pressed or glued in that will have the cork sleeve glued onto it. Then the cork is sanded down to where it is a snug fit into the female ferrule. The cork is then rubbed with wax to make it a little smoother fitting into the ferrule and will provide a moisture seal as well.

 This is a 12/64 CSE ferrule plug fitted into a blued female ferrule. It is a snug fit and adds protection to the inside of the ferrule.

 This is what the ferrule plug looks like removed from the ferrule. These fit nice and deep inside the ferrule and with a little wax applied to the cork area, provides a moisture barrier keeping the inside of the ferrule clean and dry.

 Drilling the small cork plugs that will be used in making my own ferrule plugs. I'm using a #57 drill bit here to make the hole all the way through the 1/2'' long cork plug. Believe me when I tell you that trying to drill these free hand is a disaster! This process keeps the hole centered and the right size to insert a 1/16'' brass rod.

Here are some of the components. Female ferrule that you would fit the completed plug into after the cork, brass rod and ferrule plug top has been assembled.

Below are various ferrule plug designs and materials.