Since we started officially in June of last year, we have been receiving regular questions from eager anglers as to when certain models or categories of blanks will be available. Here’s a little insight on what goes into approving a blank for production:
First, Gary has to design the pattern. This is a bigger challenge than you might think. Sometimes we have to lock Gary in the office and disconnect his phone and email. Otherwise, all of Gary’s time will be swallowed up with his fish conservation activities (Fish First, CCA, SSA), his traveling and all the calls we get from his industry reps and customers. He is a man in demand!
Once Gary designs the pattern, chooses the material and mandrel, then Brad builds a test blank. The test blank is run with our normal production, so the pattern is cut, tacked, rolled, cellophaned, baked, stripped, sanded and trimmed.
Brad then puts the blank on the flex board and we compare it to other models that we may like. Gary gives it the feel and fondle test and normally makes some changes to the pattern for a re run.
If redesign isn’t needed at that time, then Brad breaks a number of the blank model to determine the strength and see if there are any design issues.

The blank is weighed and measured at the tip, butt and its points of failure. If break strength is sufficient, Jon sends one of the unbroken models out to be built into a rod and sent out for testing. If it happens to be a category of blank that Gary is experienced with, then he will test it personally. If not, then we get it in the hands of one of our pros, someone that we know will fish it everyday.
The pro’s input is then incorporated into the model, and Gary modifies the pattern, Brad runs a new sample. The process repeats.
If the blank is perfect, we approve the final design. Final tip, butt, weight and CCS measurements are taken, a decal is ordered and the blank is ready for production.
In a perfect world, Gary hits the pattern on the first try and then the process takes only takes 2-3 weeks. More often, the process can take a month or longer.
We started designing in earnest in June 2009. We currently have 80 blank designs approved for production and ready for sale. About 20 are in the final steps of the process. We wish we were further along, but all things considered, we feel pretty fortunate to be where we are today. We’re working as hard as we can to bring you the best products that we can offer as soon as we can.