You can see, the root of the worm is nearly clean of lube due to the tiny clearanceĪ little bit of Cals was worked into the inserts before final assembly, and it all slips nicely with no resistance. It's bang on 3mm now, but it was carefully trimmed from 3.5mm, the idea was to trim minute amounts off and test fit the cap with the spacer and pawl until there was just the slightest clearance of the pawl at the root of the worm, with the cap fully tightened.
I also made a spacer for the chaser pawl. I just did by hand until everything slid through inserts nicely, with minimal slop. They did require a bit of honing by wrapping 600grit wet/dry paper around a 2mm drill bit, and used a cordless drill to spin the paper to hone, with a bit of oil for lubricant. The inserts were made on my mini lathe at home. I trimmed as much of the blank down with a thin cut-off wheel on an angle grinder, then filed it down to final shape. The OD's were drilled into the SS blank, I clamped one of the original plastic guides to the SS blank (milled from an M24 bolt on the large, using a 4 jaw chuck), to get the holes aligned. The main worm cover is 9mm, so the insert is 11mm OD, 9mm ID. So for the guide rods, which are 4mm, the sleeve insert is 6mm OD, 4mm ID.
The inserts are all 1mm thick all around. So I made another guide with delrin inserts, to reduce the sliding friction. The problem I encountered first time around was the stainless' propensity to gall on itself. I had previously attempted to make a SS level wind for this reel as I felt the plastic ones weren't strong enough. Thought I would re-visit this thread with a bit of a victory post.
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