Inside Scott Rods & Ross Reels

You don’t have to look past the Colorado Border to find great equipment manufacturers

By Paul Downing

The sun was setting over sandstone cliffs on the Frying Pan. Red spinners were everywhere and the trout were up to them. Using a 5 weight Scott S3 rod equipped with a Ross Rhythm reel, I cast to a rising brown in a riffle no more than a foot deep. My fly disappeared and I set the hook. Another Colorado trout had been fooled by a Colorado angler using a Colorado built rod and reel!

A great rod and reel adds significantly to the fun that is Colorado trout fishing. We are doubly blessed because Scott rods and Ross reels are great equipment and they are made right here in Montrose. Recently I toured both manufacturing facilities. It was a very educational experience--one I recommend highly.

Scott Rods

Before I entered the Scott Rod facility I knew nothing about rod manufacturing. What I found was a lot of dedicated crafts-persons making each rod essentially by hand. Let me take you through the process step-by-step.

We entered a large open area where a lady was carefully measuring out a section of black cloth. This, it turned out, was the graphite material from which the rod blank is formed. The material is cut wider at one end to accommodate the taper of the rod. Once cut, a machine carefully wraps the graphite cloth around a long tapered metal mandrel. The shape of the mandrel, machined to exacting tolerances, produces the scientifically designed taper of the rod. Each rod length and taper requires a separate mandrel. The exact taper is a carefully developed and well-guarded secret. It gives each rod its unique performance characteristics. The wrapped mandrel is then placed in an oven where it is heated until the graphite melts just enough to form a solid rod blank. Once the blank cools it is removed from the mandrel. The blank is a long hollow tapered tube of graphite ready to be made into a rod.

From now on it’s all hand work. First the blank is cut into sections and ferrules are hand fitted to join the sections. Scott’s rod ferrules are unique. An extra section of graphite is fit inside the hollow blank at the thicker end of the joint. This then creates the male part of the ferrule which fits inside the upper section. The result is a far more consistent bend to the rod than you will find with a lot of other rod makers. Each ferrule is fit by hand. The excess graphite of the male end is carefully ground down to fit exactly inside the upper section of the rod. A perfect fit is found when the rod is whipped back and forth without any chirping noise...called ferrule crickets. The backbone is found by flexing the rod slightly and rolling it. Each section is slightly stiffer at one point. This is the backbone and if not aligned correctly it will affect the performance of the rod. The reel seat and handle are then fitted by hand, carefully aligning the seat to the backbone of the rod.

The rod is now ready to have the eyes wrapped. This process is farmed out to stay-at-home moms and dads in the area. It gives these people an opportunity to work and take care of their family.

Finally a protective coating is applied and cured. The rod is now a thing of beauty, ready for work. The new S3 design is a joy to cast--fast but with plenty of feel. My 7 weight casts a small dry fly with finesse but has the butt strength to whip a silver salmon.

Ross Reels

Entering the Ross Reel facility I was impressed with the vast difference in techniques compared to Scott. Here a large part of the manufacturing process is accomplished by modern computer driven milling machines. Starting with a case hardened aluminum bar stock cut to a precise length, the machine automatically goes through multiple processes. The result is a reel seat or a reel spool complete to the last detail, including threaded screw holes. Tolerances are an incredible 0.0006 of an inch. Watching this complicated machine transform the bar stock is fascinating.

Next, each part is debarred by hand and tumbled to remove sharp edges. It is now ready for the finish to be applied. This is done by an outside contractor.

When the finished parts are returned, they are ready for assembly. Foot, seat, spool, drag assembly and handle are carefully fit by hand. This hand process ensures that each reel performs perfectly.

I loved my old Gunnison reels and was upset when Ross announced their discontinuance. I never thought I would say it, but the new Rhythm and Evolution reels are even better! These modern, large arbor designs are precision machines which perform as smoothly and trouble free as their predecessor while being lighter and more attractive. Gone is the ball bearing arbor. The tolerances are so close it is not needed. I prefer a light drag. These reels have no hesitation and little drag increase as line and backing are played out.

If you get a chance, arrange for a visit to both companies. The experience is fascinating. Visit your local fly shop to try their offerings or contact Scott Rods at   800-728-7208 and Ross Reels at 800-336-1050.

About The Author

Paul Downing is a lifetime member of TU. He writes extensively for Colorado Fishing & Hunting News, as well as several other fly fishing magazines. His book, Handbook of Western Fly Fishing, has been very favorably received. For a copy, contact Majestic Press, Inc., 800-468-0324, or email, majesticpress@aol.com.