Mastering Rod Building

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with longtime rod builder and RodMaker Magazine publisher Tom Kirkman about how reducing unnecessary weight can improve fishing rod performance without sacrificing strength or durability.

Bill and Tom discuss some of the biggest opportunities to cut weight in a custom build, including FUJI Titanium Guides, MC Guides, Torzite Guides, and Carbon Fiber Grips. They explain why weight in the upper half of the rod matters most and how lighter guides, smaller components, shorter wraps, and less finish can improve rod speed, recovery, and overall efficiency.

The conversation also moves into the handle, where carbon fiber grips, grip coring, lightweight arbors, and proper reel-seat installation can remove significant weight. Tom explains how builders can maintain the look and craftsmanship of a custom rod while eliminating material that adds weight without improving performance.

Bill and Tom also discuss rod balance, sensitivity, guide selection, and why custom builders should not be afraid to mix components or modify traditional setups to get the performance they want.

Throughout the episode, Tom emphasizes a simple principle: do the most with the least. The goal is not to make a rod as light as possible at all costs, but to use components and building techniques that produce the lightest rod capable of reliably doing its intended job.

Mastering Rod Building is brought to you by Anglers Resource — your source for genuine Fuji Tackle components.

Where to buy genuine FUJI®️ rod components (Area Distributors)

Japan: FIRST Corporation — https://first-fuji.co.jp/ • [email protected]

American Continent (North & South America): Anglers Resource — https://anglersresource.net/ • [email protected]

Oceania: Frogleys Offshore — https://fujitackle.com.au • [email protected]

Spain/Czech/Finland/Sweden/Estonia/Latvia/Poland/Denmark/Belgium/Germany/Netherlands/Ireland/Luxembourg/France/Portugal/UK/Norway/Belarus/Ukraine/Russia:: CALICO S.A. (Kalikunnan) — https://kalikunnan.com/ • [email protected]

Europe: MAJORA Intelligent Fishing (FUJI Tackle Italy) — https://www.fujitackle.it • [email protected]

Asia: KOWA Company, Ltd. — [email protected]

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with longtime angler, outdoor media personality, and rod builder Jim Crowley about how decades of tournament fishing, television, writing, lure building, and product development have shaped the way he approaches custom fishing rods. Crowley shares how his fishing career evolved from competitive angling into outdoor television and radio before eventually leading him into rod building.

Jim explains how his early work with St. Croix and rod designer Mike Thorson taught him to think closely about rod length, power, action, and matching a rod to a specific fishing technique. Years later, encouragement from Don Morse helped push him into building his own rods when he realized he wanted combinations of actions and lengths that he was not finding in off-the-shelf equipment.

The conversation explores why Jim believes building his own rods has actually made him a better angler. He explains that designing a rod around a particular lure forces him to pay closer attention to every part of the fishing system, including the rod, reel, line, lure presentation, retrieve speed, and what the bait is doing throughout every cast.

Bill and Jim also dive into the development of Jim’s technique-specific rod kits with Mud Hole, including rods designed specifically for bladed jigs, hair jigs, jerkbaits, and Ned rigs. Jim breaks down the years of experimentation behind his bladed-jig setup, from testing different lines and rod actions to eventually settling on a composite blank that provides enough sensitivity to detect a bite while still allowing the rod to load deeply and keep fish pinned.

Jim also shares the story behind his hair-jig rod and why a 1/16-ounce hair jig can be such an effective tool for smallmouth bass and other species. He explains the importance of long casts, slow retrieves, light line, and a rod with enough parabolic action to serve as a shock absorber when fishing tiny hooks and light tackle. The conversation includes examples from recent trips where the hair jig produced quality smallmouth when other techniques struggled.

Bill and Jim finish by discussing downsized bladed jigs, matching lure size to young-of-the-year forage, building rods around highly specialized fishing techniques, and the satisfaction that comes from catching fish on equipment you designed and built yourself. Jim emphasizes that custom rod building is not simply about creating a fishing rod—it can help anglers understand their equipment, presentation, and fishing techniques at a much deeper level.

Mastering Rod Building is brought to you by Anglers Resource — your source for genuine Fuji Tackle components.

Where to buy genuine FUJI®️ rod components (Area Distributors)

Japan: FIRST Corporation — https://first-fuji.co.jp/ • [email protected]

American Continent (North & South America): Anglers Resource — https://anglersresource.net/ • [email protected]

Oceania: Frogleys Offshore — https://fujitackle.com.au • [email protected]

Spain/Czech/Finland/Sweden/Estonia/Latvia/Poland/Denmark/Belgium/Germany/Netherlands/Ireland/Luxembourg/France/Portugal/UK/Norway/Belarus/Ukraine/Russia:: CALICO S.A. (Kalikunnan) — https://kalikunnan.com/ • [email protected]

Europe: MAJORA Intelligent Fishing (FUJI Tackle Italy) — https://www.fujitackle.it • [email protected]

Asia: KOWA Company, Ltd. — [email protected]

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with longtime rod builder and RodMaker Magazine publisher Tom Kirkman about one of the most common questions in custom rod building: how to price a custom fishing rod and build a business that is actually worth the builder’s time.

Tom explains why custom rod builders should not try to compete with factory rods on price and why a well-built custom rod should command a premium. He shares the advice that helped shape his own approach to pricing, including starting with the price of a comparable high-end factory rod, understanding what the local market will bear, and recognizing that if no customers ever hesitate because of price, a builder may be charging too little.

The conversation covers component costs, labor, profit margins, warranties, customer-supplied components, rod repair, and why charging an hourly labor rate can actually penalize experienced builders for becoming more efficient. Bill and Tom also discuss how reputation, craftsmanship, specialization, and a recognizable building style can increase the value of a rod beyond the cost of the materials used to build it.

Tom explains why successful builders need to offer something factory manufacturers cannot, whether that means tailoring a rod to an individual angler, solving a specific fishing problem, creating unique aesthetics, or serving a niche technique. He also shares ideas for growing a custom rod business through rod repair, tackle shops, craft shows, gift certificates, and other opportunities that put builders directly in front of potential customers.

Bill and Tom also discuss warranties, pricing enough margin into each rod to cover legitimate failures, and the federal Sport Fishing Equipment Excise Tax that custom rod builders need to understand when selling rods. Throughout the conversation, Tom emphasizes that there is no universal price for a custom rod. Builders have to understand their market, the quality and value of their work, and what they ultimately want their rod-building business to accomplish.

Mastering Rod Building is brought to you by Anglers Resource — your source for genuine Fuji Tackle components.

Where to buy genuine FUJI®️ rod components (Area Distributors)

Japan: FIRST Corporation — https://first-fuji.co.jp/ • [email protected]

American Continent (North & South America): Anglers Resource — https://anglersresource.net/ • [email protected]

Oceania: Frogleys Offshore — https://fujitackle.com.au • [email protected]

Spain/Czech/Finland/Sweden/Estonia/Latvia/Poland/Denmark/Belgium/Germany/Netherlands/Ireland/Luxembourg/France/Portugal/UK/Norway/Belarus/Ukraine/Russia:: CALICO S.A. (Kalikunnan) — https://kalikunnan.com/ • [email protected]

Europe: MAJORA Intelligent Fishing (FUJI Tackle Italy) — https://www.fujitackle.it • [email protected]

Asia: KOWA Company, Ltd. — [email protected]

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with longtime West Coast rod builder Bill “Salty Dawg” Havens about his decades in the craft, the development of rail rods, and the innovations that helped shape Southern California’s long-range fishing scene.

Bill shares how he began building rods in the 1960s, eventually turning rod building into a profession and developing the Salty Dawg rail grip after seeing traditional foregrips get destroyed while fighting large tuna from the rail. He explains how rail rods evolved, why durability matters, and how his grip design eventually became part of the Batson product lineup.

The conversation covers heavy-duty rod construction, guide wraps, thread size, epoxy and finish techniques, grip installation, and Bill’s approach to finding faster and more efficient ways to produce custom work. Bill also discusses developing photo wraps, experimenting with materials for decorative designs, and working alongside builders such as Jim Trelikes as techniques like dragon scales and other decorative styles evolved.

Bill and Bill also discuss the importance of sharing techniques, giving credit to the builders who developed them, and how younger rod builders continue adapting old ideas with new materials and technology. Bill reflects on thousands of rods built over his career, his work with Fisherman’s Landing and Batson, and why craftsmanship, efficiency, experimentation, and teaching others have remained central to his approach.

Mastering Rod Building is brought to you by Anglers Resource — your source for genuine Fuji Tackle components.

Where to buy genuine FUJI®️ rod components (Area Distributors)

Japan: FIRST Corporation — https://first-fuji.co.jp/ • [email protected]

American Continent (North & South America): Anglers Resource — https://anglersresource.net/ • [email protected]

Oceania: Frogleys Offshore — https://fujitackle.com.au • [email protected]

Spain/Czech/Finland/Sweden/Estonia/Latvia/Poland/Denmark/Belgium/Germany/Netherlands/Ireland/Luxembourg/France/Portugal/UK/Norway/Belarus/Ukraine/Russia:: CALICO S.A. (Kalikunnan) — https://kalikunnan.com/ • [email protected]

Europe: MAJORA Intelligent Fishing (FUJI Tackle Italy) — https://www.fujitackle.it • [email protected]

Asia: KOWA Company, Ltd. — [email protected]

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with longtime rod builder and product developer Andy Dear about craftsmanship, creativity, and developing a personal rod-building point of view.

Andy explains why his approach centers on performance, simplicity, and creating a deeper connection to fishing rather than adding decoration that does not serve a purpose.

The conversation covers Andy’s background in rod building, woodworking, music, carbon-fiber grips, finish development, and the industry innovators and memorable personalities who influenced the craft.

Bill and Andy also discuss ego, social-media arguments, differing building methods, and why rod builders should focus on executing their work well, respecting other approaches, and enjoying the community surrounding the craft.

The episode also includes details on the 2026 Mastering Rod Building Seminar, happening August 14–16 at the Orange Beach Event Center at The Wharf in Orange Beach, Alabama. For more information, email Jack Barron at [email protected] or call 251-943-4491.

Mastering Rod Building is brought to you by Anglers Resource — your source for genuine Fuji Tackle components.

Where to buy genuine FUJI®️ rod components (Area Distributors)

Japan: FIRST Corporation — https://first-fuji.co.jp/ • [email protected]

American Continent (North & South America): Anglers Resource — https://anglersresource.net/ • [email protected]

Oceania: Frogleys Offshore — https://fujitackle.com.au • [email protected]

Spain/Czech/Finland/Sweden/Estonia/Latvia/Poland/Denmark/Belgium/Germany/Netherlands/Ireland/Luxembourg/France/Portugal/UK/Norway/Belarus/Ukraine/Russia:: CALICO S.A. (Kalikunnan) — https://kalikunnan.com/ • [email protected]

Europe: MAJORA Intelligent Fishing (FUJI Tackle Italy) — https://www.fujitackle.it • [email protected]

Asia: KOWA Company, Ltd. — [email protected]

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with legendary custom rod builder James "Doc Ski" Labanowski about his lifetime in rod building and the evolution of decorative thread work.

Doc shares how he began wrapping guides at eight years old, served 23 years as a U.S. Navy corpsman, and eventually learned every part of custom rod building from the Harrington Rod Company.

The conversation covers Doc’s role in developing color-change weaving and his approach to the Throop Tiger Wrap, including how thread direction, spacing, burnishing, color selection, and finish coats create its distinctive patterns.

Bill and Doc also discuss the importance of teaching others, recognizing the innovators behind different techniques, and using rod building to support veterans through organizations such as Salmon for Soldiers and Project Healing Waters.

The episode also includes details on the 2026 Mastering Rod Building Seminar, happening August 14–16 at the Orange Beach Event Center at The Wharf in Orange Beach, Alabama. For more information, email Jack Barron at [email protected] or call 251-943-4491.

Mastering Rod Building is brought to you by Anglers Resource — your source for genuine Fuji Tackle components.

Where to buy genuine FUJI®️ rod components (Area Distributors)

Japan: FIRST Corporation — https://first-fuji.co.jp/ • [email protected]

American Continent (North & South America): Anglers Resource — https://anglersresource.net/ • [email protected]

Oceania: Frogleys Offshore — https://fujitackle.com.au • [email protected]

Spain/Czech/Finland/Sweden/Estonia/Latvia/Poland/Denmark/Belgium/Germany/Netherlands/Ireland/Luxembourg/France/Portugal/UK/Norway/Belarus/Ukraine/Russia:: CALICO S.A. (Kalikunnan) — https://kalikunnan.com/ • [email protected]

Europe: MAJORA Intelligent Fishing (FUJI Tackle Italy) — https://www.fujitackle.it • [email protected]

Asia: KOWA Company, Ltd. — [email protected]

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with Roger Hinchcliff of Lamiglas and the Steelhead Manifesto about steelhead fishing, Lamiglas rods, and what rod builders need to know when building technique-specific steelhead rods.

Roger shares how he got started fishing as a kid in Michigan, spending countless hours on the Huron River catching bait, reading water, and learning to fish for everything from bluegill and smallmouth to walleye, pike, and eventually steelhead.

Bill and Roger discuss Roger’s background in the fishing industry, including founding Steelhead Manifesto, building a large online following, winning River Angler of the Year in 2013, and his long career with Lamiglas, where he now serves as vice president.

The conversation covers the differences between Great Lakes and West Coast steelhead fishing, including drift fishing, back bouncing, float fishing, centerpin rods, spoon rods, spinner rods, leader sizes, reel choices, and why steelhead rod length, power, action, and guide size should always match the technique and water.

Roger also explains cold-weather steelhead fishing, including why larger guides help with ice, how anglers manage braid and mono in freezing conditions, and why sensitivity and line control are so important when fishing light leaders for powerful fish.

The episode also goes into steelhead behavior, fish memory, color selection, fishing pressure, and why anglers should carry multiple presentations instead of relying on one bait or one technique.

The episode also includes details on the 2026 Mastering Rod Building Seminar, happening August 14–16 at the Orange Beach Event Center at The Wharf in Orange Beach, Alabama. For more information, email Jack Barron at [email protected] or call 251-943-4491.

Mastering Rod Building is brought to you by Anglers Resource — your source for genuine Fuji Tackle components.

Where to buy genuine FUJI®️ rod components (Area Distributors)

Japan: FIRST Corporation — https://first-fuji.co.jp/ • [email protected]

American Continent (North & South America): Anglers Resource — https://anglersresource.net/ • [email protected]

Oceania: Frogleys Offshore — https://fujitackle.com.au • [email protected]

Spain/Czech/Finland/Sweden/Estonia/Latvia/Poland/Denmark/Belgium/Germany/Netherlands/Ireland/Luxembourg/France/Portugal/UK/Norway/Belarus/Ukraine/Russia:: CALICO S.A. (Kalikunnan) — https://kalikunnan.com/ • [email protected]

Europe: MAJORA Intelligent Fishing (FUJI Tackle Italy) — https://www.fujitackle.it • [email protected]

Asia: KOWA Company, Ltd. — [email protected]

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with longtime custom rod builder Mark Crouse, also known as the Munich Rod Man, about 52 years of rod building, custom craftsmanship, 3D printing, carbon fiber grips, and building a recognizable personal style.

Mark shares how he started fishing as a child and built his first rod at age 12 after his mother brought home a blank from a closing sporting goods store. With limited access to parts in Germany, he learned to improvise with parachute cord, electrical tape, goose quills, and whatever materials he could find.

Bill and Mark discuss Mark’s wide range of rod building skills, including decorative wraps, cork, wood, birch, acrylic, carbon fiber, marbling, finish work, custom butt caps, reel seats, trim pieces, and ergonomic grip designs.

The conversation also goes deep on how Mark is using 3D printing to create custom reel seats, winding checks, grip shells, trim parts, and carbon fiber-covered handles. He explains filament choices, printer setup, heat resistance, wall thickness, carbon fiber sleeves, and why 3D printing gives rod builders new ways to create truly one-of-a-kind components.

Mark also shares thoughts on matte finishes, ultralight rods, fly rod handle fit, hydro dipping, custom inlays, and why serious rod builders should focus on developing their own style instead of copying someone else’s work.

The episode also includes details on the 2026 Mastering Rod Building Seminar, happening August 14–16 at the Orange Beach Event Center at The Wharf in Orange Beach, Alabama. The weekend will feature hands-on rod building education, seminars, meals, a Saturday crawfish and shrimp boil, discounted lodging nearby, and fellowship with the rod building community. For more information, email Jack Barron at [email protected] or call 251-943-4491.

Mastering Rod Building is brought to you by Anglers Resource — your source for genuine Fuji Tackle components.

Where to buy genuine FUJI®️ rod components (Area Distributors)

Japan: FIRST Corporation — https://first-fuji.co.jp/ • [email protected]

American Continent (North & South America): Anglers Resource — https://anglersresource.net/ • [email protected]

Oceania: Frogleys Offshore — https://fujitackle.com.au • [email protected]

Spain/Czech/Finland/Sweden/Estonia/Latvia/Poland/Denmark/Belgium/Germany/Netherlands/Ireland/Luxembourg/France/Portugal/UK/Norway/Belarus/Ukraine/Russia:: CALICO S.A. (Kalikunnan) — https://kalikunnan.com/ • [email protected]

Europe: MAJORA Intelligent Fishing (FUJI Tackle Italy) — https://www.fujitackle.it • [email protected]

Asia: KOWA Company, Ltd. — [email protected]

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with legendary caster and rod designer Steve Rajeff about world-class casting, rod design, and the performance details that separate good rods from elite-level tools.

Steve shares how he got started fishing as a kid in San Francisco, learned fly casting at the Golden Gate Angling and Casting Club, and was mentored by names like Mel Krieger before becoming a world champion caster as a teenager.

Bill and Steve discuss Steve’s early work with graphite and boron rods, his time at Sage, and his long career at G. Loomis, where he helped design thousands of rods across fly, bass, spinning, casting, saltwater, and specialty categories.

The conversation also covers Team USA casting, the American Casting Association, the upcoming World Fly Casting Championships in Italy, and how elite casters think about rod weight, guide spacing, line speed, blank design, and components like Fuji titanium Torzite single-foot guides.

Steve explains the differences between fishing rods and competition casting rods, including why lighter blanks, smaller guides, moderate actions, shooting heads, monofilament running lines, and precise guide placement all matter when chasing maximum distance and accuracy.

The episode also includes details on the 2026 Mastering Rod Building Seminar, happening August 14–16 at the Orange Beach Event Center at The Wharf in Orange Beach, Alabama. The weekend will feature hands-on rod building education, seminars, meals, a Saturday crawfish and shrimp boil, discounted lodging nearby, and fellowship with the rod building community. For more information, email Jack Barron at [email protected] or call 251-943-4491.

Mastering Rod Building is brought to you by Anglers Resource — your source for genuine Fuji Tackle components.

Where to buy genuine FUJI®️ rod components (Area Distributors)

Japan: FIRST Corporation — https://first-fuji.co.jp/ • [email protected]

American Continent (North & South America): Anglers Resource — https://anglersresource.net/ • [email protected]

Oceania: Frogleys Offshore — https://fujitackle.com.au • [email protected]

Spain/Czech/Finland/Sweden/Estonia/Latvia/Poland/Denmark/Belgium/Germany/Netherlands/Ireland/Luxembourg/France/Portugal/UK/Norway/Belarus/Ukraine/Russia:: CALICO S.A. (Kalikunnan) — https://kalikunnan.com/ • [email protected]

Europe: MAJORA Intelligent Fishing (FUJI Tackle Italy) — https://www.fujitackle.it • [email protected]

Asia: KOWA Company, Ltd. — [email protected]

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with Carlos “Carlitos” Sanchez of Carlitos 395 Custom Rods about California’s ultralight trout scene, custom trout rods, and the specialized gear anglers use to target big trout on light tackle.

Carlos shares how a high school friend introduced him to fishing and how he later got into rod building through BB Custom Rods. What started as helping with prep work and handles eventually turned into his own growing custom rod business, focused heavily on California trout anglers.

Bill and Carlos discuss why trout fishing in California is so unique, from private and pay lakes to the Eastern Sierra and Santa Ana River Lakes. They cover big stocked rainbows, lightning trout, trout tournaments, mini jigs, spoons, light braid, fluorocarbon leaders, and the serious high-end setups many anglers use.

Carlos explains why his trout rods are usually 7’6” to 8’ long, giving anglers better casting distance with tiny jigs and spoons from shore. He also talks about developing his own blanks, using fast actions with a slightly softer tip to work mini jigs, drop shots, and spoons while still having enough backbone for larger trout.

The conversation also covers Fuji titanium AT guides, lightweight guide trains, size 5 running guides, one-coat finish work, Tennessee-style handles, sliding rings, carbon grips, and why keeping ultralight rods balanced and sensitive matters so much.

Bill and Carlos wrap up by talking about lure colors, bait makers like Trucha Spoons, Trout Vet Custom Baits, Get Bent Customs, and SoCal Trout Cartel, plus Carlos’s Carlitos 395 branding and connection to Highway 395 and the Eastern Sierra. Overall, this episode is a deep look at California trout fishing, ultralight rod design, and the innovation coming from a highly specialized fishing community.

Mastering Rod Building is brought to you by Anglers Resource — your source for genuine Fuji Tackle components.

Where to buy genuine FUJI®️ rod components (Area Distributors)

Japan: FIRST Corporation — https://first-fuji.co.jp/ • [email protected]

American Continent (North & South America): Anglers Resource — https://anglersresource.net/ • [email protected]

Oceania: Frogleys Offshore — https://fujitackle.com.au • [email protected]

Spain/Czech/Finland/Sweden/Estonia/Latvia/Poland/Denmark/Belgium/Germany/Netherlands/Ireland/Luxembourg/France/Portugal/UK/Norway/Belarus/Ukraine/Russia:: CALICO S.A. (Kalikunnan) — https://kalikunnan.com/ • [email protected]

Europe: MAJORA Intelligent Fishing (FUJI Tackle Italy) — https://www.fujitackle.it • [email protected]

Asia: KOWA Company, Ltd. — [email protected]