Bob Sirois 
ezOP
(3/22/01 11:01 am)
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Step#6, Shape and sand the handle.
For this step, you want to make sure the rod is secure in the drill stock center and the rod supports. For previous steps I might have only run the reinforced tape once across the rod butt to catch it, but in the sanding process a good amount of force will be applied. You need to run the reinforced tape back and forth between the rod butt and tail stock center several times. 
I like to take my shop vac and using some metal banding, staple the floor attachment to my shop bench. With the vac running the cork dust is picked up and doesn't get all over the shop. Before starting run some masking tape over the reel seat and the blank ahead of the foregrip to protect it should you catch either with the sanding block. This particular tenn handle is without any reel seat, but you need to protect both the seat and the blank. Turn the vac on and the drill on constant and high speed. Take the sanding block and start working it back and forth evenly and firmly. The key to this step is to use just enough pressure, work evenly and slowly. 
Have an idea what diameter handle you want based on what feels comfortable in your hands and have your calipers handy. It's important to stop occassionally, take the calipers and run them down the length of the handle, to insure that you aren't taking off too much cork at one end or the other or in the middle. If you are then take a smaller sanding block and work the high spots, then go back to the long block. 
After you have the handle down to the diameter you want, start working it with strips of 200 grit, 400 grit and maybe 600 grit wet dry sandpaper. I like wet dry paper, because it is more durable and the same strips can handle numerous sanding jobs before needing replacement. Run the doubled over strips back and forth to get the final smoothness desired. For rounding the foregrip near the blank, first take a small sanding block and run it up to the foregrip to square it, then up the foregrip to round it to the shape desired. If you want the foregrip tapered, the when you start sanding/shaping, hold the sanding block along it's length at the taper angle desired.
We will glue on the butt cap and seal the cork down the road.
Tight Lines
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