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Assembling Your 12’ 6:4 BYO Kit - Instruction Manual Congratulations on the purchase of your 12’ 6:4 BYO Kit. Follow these easy-to-follow steps to build a simple tenkara fly
fishing rod that will give you years of enjoyment, performance and that self-made feel. We recommend reading through
these instructions at least once before beginning assembly.
Additional supplies recommended: Paper towels, sharp knife, 70% or 91% isopropyl alcohol, pencil, permanent marker,
scissors, and disposable gloves.
Note: If you purchased your BYO Kit with the optional Winn® tenkara grip and wish to mount it with 2-sided golf grip
tape and odorless mineral spirits (not supplied), please refer to the ‘How To’ section of our website for links to videos
demonstrating this method.
- You are going to build this simple fishing rod - (Actual rod may vary depending on options purchased)
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Step 1. Identify the components
The thin Tip section is very fragile. Resist the temptation to bend and ‘test the flexibility’ of the rod Tip section.
Butt cap Rod cap
Butt cap insert
ert
WC ring
Handle section
Tip section with red lilian
Cork handle
Cotton swabs Epoxy mixing squares
Alcohol cleaning pads 5-min epoxy (X1) 45-min epoxy (X2)
Mixing sticks
Sandpaper Toothpick
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Step 2. Prepare your work surface Clear off an area on a table or work bench. Lay a few paper towels or newspaper down on your work surface. Epoxy is sticky and seems to find its way onto every surface you don’t want, however, it is easily cleaned up before it cures with isopropyl alcohol. You may wish to use disposable gloves while working with epoxy. Step 3. Mark the butt cap insert NOTE: The edges of the aluminum butt cap insert may be sharp! (Figure 2) Mark the butt cap insert with an “X” on the
threaded end (Figures 1 & 2). The threaded end needs to be at the butt end (glossy or non-painted end) of the Handle
section(biggest blank section) so the butt cap can screw into it. Locate your rod Handle section and slide out the other
sections from within it, keeping them together as a unit and place them out of the way. Slide the marked butt cap insert
halfway onto the Handle section’s glossy or non-painted end until it reaches the threads (See Figure 2). If the butt cap
insert is too tight, DO NOT force it on with the palm of your hand as this could result in a cut! If needed, GENTLY scuff
sand the handle section with the supplied sandpaper until it fits (Figure 3). Wipe of excess dust with a paper towel.
Avoid breathing this dust. Mark the position on the Handle section with a pencil (Figure 4).
Figure 1 Figure 2
Figure 3 Figure 4
Threaded end Non-Threaded end
Glossy or non-painted end of
Handle section
Scuff sand if necessary
Edges may be sharp!
Butt cap insert
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Step 4. Glue on the butt cap insert Clean the butt end of blank using an alcohol cleaning pad. Using a pair of scissors, open both sides of the 5-minute
epoxy pack and squeeze contents onto an epoxy mixing square. Mix epoxy gently in a circular motion for about 1
minute (Figure 5). Apply the epoxy around the Handle section from the butt end to the pencil mark (Figure 6). Slide the
butt cap insert onto the handle section, twisting it as your push up to the pencil mark, allowing excess epoxy to drip onto
the work surface. Clean excess epoxy on the handle section with an alcohol prep pad or a paper towel and isopropyl
alcohol (Figure 7). A little epoxy on the Handle section is fine as you will be applying more epoxy to the Handle section
in the next step. Allow epoxy to cure for about 1 hour (Figure 8). NOTE: Keep your epoxy mixing square aside so that
you can test it for curing progress. If it sets nice and hard within an hour, you are ready for the next step!
Figure 5 Figure 6
Figure 7 Figure 8
Allow epoxy to cure in this position
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Step 5. Mark the cork handle position Your cork handle may come sealed in a plastic sleeve which will protect it during assembly. If you purchased a Winn®
Tenkara Grip with your kit, follow these same instructions if you want to attach it with epoxy. Note that one end of the
cork handle is larger in diameter and has a larger opening designed to accommodate the butt cap insert. Test fit the
cork handle (large end first) onto the Handle section and over the butt cap insert, twisting the cork handle as you near
the end may help (Figure 9). Note: Although the cork handle is ‘Pre-fitted’, experienced rod builders may wish to further
ream or shim the cork handle as desired. You want the butt cap insert to be slightly recessed inside the cork handle
about 1mm (Figure 10). This allows the removable butt cap to seal against the surface of the cork handle and not
bottom out on the butt cap insert. Mark the Handle section with a pencil where it meets the top of the cork handle (See
Figure 11). Remove the cork handle and lightly clean the entire Handle section and butt cap insert with an alcohol
cleaning pad.
Figure 9 Figure 10
Figure 11
Slightly recess the butt cap insert
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Step 6. Glue on the cork handle Using a pair of scissors, cut open both packs of 45-minute epoxy and squeeze contents onto an epoxy mixing square.
Mix for about 1 minute. Use your mixing stick to thoroughly apply the epoxy to the area between the pencil mark on
the handle section all the way down to and over the butt cap insert. Keep turning the rod to avoid excess dripping of the
epoxy. Slide the cork handle(larger end first) onto the Handle section, twisting the cork handle as you slide it over the
epoxy (See Figure 12). You may wish to hold the project vertically with the butt cap insert at the top as the cork handle
gets near its final position (See Figure 13). Just before the cork handle reaches the end of the butt cap insert, use a
cotton swab to remove the excess epoxy (See figure 14). This will reduce the chance of getting epoxy inside the threads
of the butt cap insert. Slide the cork handle slightly past the end of the butt cap insert, allowing the butt cap insert to
recess about 1mm (See Figure 15). Wipe off any excess epoxy that may have gone into the threads of the butt cap insert
with a cotton swab. These threads must be clean and free of epoxy for the butt cap to thread in later. If some epoxy got
under the protective plastic on the cork handle, simply peel the plastic back and clean with an alcohol cleaning pad. You
should have time to continue to Step 7 before your 45-minute epoxy sets up.
Figure 12 Figure 13
Figure 14 Figure 15
Final cork handle position
Wet epoxy
Butt cap insert is slightly recessed
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Step 7. Glue on the WC ring
Locate your WC ring. Use the supplied toothpick to make a very small ring of epoxy around the top of the cork handle
where it meets the handle section (Figures 16 & 17). Slide the WC ring onto the handle and press into the epoxy (Figure
18). Clean up excess epoxy with a cotton swab and alcohol cleaning pad (Figure 19). Remove plastic sleeve from the
cork handle with a sharp knife (Figures 20 & 21). Allow your tenkara rod to completely cure overnight.
Figure 16 Figure 17
Figure 18 Figure 19
Figure 20 Figure 21
Slide WC ring onto epoxy
Apply a very small amount of epoxy here
Epoxy area shown in red
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Step 8. Insert rod sections, butt cap, and rod cap
Carefully insert the remaining rod sections through the back of the butt cap insert, keeping the delicate tip section inside
the other sections (Figure 22). Screw in the butt cap (See Figure 23). Tie a simple square knot in the end of your lilian if
not already pre-tied (Figure 24). Carefully push your rod cap into the top of the handle section; a little ‘nose grease’ may
help it slide easier (Figure 25).
Figure 22 Figure 23
Figure 24 Figure 25
Step 9. Go Fish! Congratulations! You have successfully built your own tenkara rod! Your new tenkara rod is 100% fish-ready now. If
you would like to further customize your tenkara rod, there are many good websites demonstrating how to add thread
wraps, decals, etc. and finish them with Flex Coat and other rod finishing products. Read the information below if you
are new to tenkara. These tips will guide you through the basic opening and closing of your tenkara rod as well as
attaching and removing fishing line from your lilian.
Tie a square knot
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Opening and closing your tenkara rod
There are lots of great videos on the internet demonstrating how to properly and safely extend and collapse your
tenkara rod. To open, remove your rod cap, place your thumb and forefinger along the top end of the rod handle
section while you slowly pull the smaller sections out with your other hand. You will notice the sections fit into each
other. A light pinching resistance is all that is needed to properly secure each section (See Figure 26). To collapse your
rod, start from the base (NEVER COLLAPSE FROM THE TIP SECTION) and slowly collapse each section, one at a time into
each other. If a section is hard to collapse, a light tapping of that section will usually break it loose (See Figure 27).
Figure 26 Figure 27
Attaching fishing line to the lilian Most level lines are easily attached to your tenkara rod lilian with a simple slip knot. With the thin Tip section still inside
the Handle section, extend the lilian only(See Figure 28). Loop the lilian through the slip knot in the level line twice (See
Figure 29). Pull on the level line to close the loop and tighten the knot (Figure 30). To remove the level line, simply pull
the small tag end of your slip knot (Figure 31).
Figure 28 Figure 29
Level line Lilian
Light pinching pressure here Hold handle of rod
Pull with this hand
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Figure 30 Figure 31
Sectional view of your tenkara rod This image shows the butt cap insert, cork handle and WC ring in place. Notice that the rod handle section passes through the butt cap insert about half way.
We hope you enjoyed your BYO Kit project. Feel free to leave an honest review of your BYO Kit experience at:
Tenkaracustoms.com
Pull to tighten
Pull to loosen
Handle section Cork handle
(Steps 5 and 6)
Butt cap insert
(Steps 3 and 4)
Tenkara Customs
WC Ring
(Step 7)