Making a rod case that will protect your rod through years of fishing trips requires care, technique and experience. Over 30+ years, we've learned the best processes for making cases that perform at the highest levels. Below is a general overview of the process we use for manufacturing our rod tubes.
STEP 1: Cut the Pipe
We use industrial strength thin wall (for a light-weight feel) PVC pipe for our USA made rod tubes. We get the pipe in bulk orders, then cut each pipe individually to the length needed. Cutting out the reel pouch has to be done right to ensure that the strength of the tube is not compromised. The tube section is then sanded down to eliminate any sharp edges that can tear the fabric.
STEP 2: Line the Pipe
The tube is then lined with 200 denier polyester liner and secured on both ends. Unlike imported tubes, our liners are sewn shut at the bottom, so your rod segments are being suspended above the ground. Other brands have open ended liners so all that is between your rod segment and the ground is the thin piece of outer covering.
STEP 3: Sew the Outer Cover
Our expert sewers can sew the tube covering to within 1/32nd of an inch, creating a very tight fit over the pipe. The patterns are cut in bulk and sewn to tight specifications.
STEP 4: The Finished Product
After the cutters and sewers are done producing the outer cover, and the pipe is cut and lined, another team builds the finished product. The covers are such a tight fit that some tubes require 2 people to fit the outer cover over the tube. Once the tube is fit, they are cleaned, bagged and tagged and made ready to ship.