Mastering Rod Building

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with longtime West Coast rod builder Bill “Salty Dawg” Havens about his decades in the craft, the development of rail rods, and the innovations that helped shape Southern California’s long-range fishing scene.

Bill shares how he began building rods in the 1960s, eventually turning rod building into a profession and developing the Salty Dawg rail grip after seeing traditional foregrips get destroyed while fighting large tuna from the rail. He explains how rail rods evolved, why durability matters, and how his grip design eventually became...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with longtime rod builder and product developer Andy Dear about craftsmanship, creativity, and developing a personal rod-building point of view.

Andy explains why his approach centers on performance, simplicity, and creating a deeper connection to fishing rather than adding decoration that does not serve a purpose.

The conversation covers Andy’s background in rod building, woodworking, music, carbon-fiber grips, finish development, and the industry innovators and memorable personalities who influenced the craft.

Bill and Andy also discuss ego, social-media arguments, differing bu...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with legendary custom rod builder James "Doc Ski" Labanowski about his lifetime in rod building and the evolution of decorative thread work.

Doc shares how he began wrapping guides at eight years old, served 23 years as a U.S. Navy corpsman, and eventually learned every part of custom rod building from the Harrington Rod Company.

The conversation covers Doc’s role in developing color-change weaving and his approach to the Throop Tiger Wrap, including how thread direction, spacing, burnishing, color selection, and finish co...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with Roger Hinchcliff of Lamiglas and the Steelhead Manifesto about steelhead fishing, Lamiglas rods, and what rod builders need to know when building technique-specific steelhead rods.

Roger shares how he got started fishing as a kid in Michigan, spending countless hours on the Huron River catching bait, reading water, and learning to fish for everything from bluegill and smallmouth to walleye, pike, and eventually steelhead.

Bill and Roger discuss Roger’s background in the fishing industry, including founding Steelhead Manifesto, building a large on...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with longtime custom rod builder Mark Crouse, also known as the Munich Rod Man, about 52 years of rod building, custom craftsmanship, 3D printing, carbon fiber grips, and building a recognizable personal style.

Mark shares how he started fishing as a child and built his first rod at age 12 after his mother brought home a blank from a closing sporting goods store. With limited access to parts in Germany, he learned to improvise with parachute cord, electrical tape, goose quills, and whatever materials he could find.<...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with legendary caster and rod designer Steve Rajeff about world-class casting, rod design, and the performance details that separate good rods from elite-level tools.

Steve shares how he got started fishing as a kid in San Francisco, learned fly casting at the Golden Gate Angling and Casting Club, and was mentored by names like Mel Krieger before becoming a world champion caster as a teenager.

Bill and Steve discuss Steve’s early work with graphite and boron rods, his time at Sage, and hi...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with Carlos “Carlitos” Sanchez of Carlitos 395 Custom Rods about California’s ultralight trout scene, custom trout rods, and the specialized gear anglers use to target big trout on light tackle.

Carlos shares how a high school friend introduced him to fishing and how he later got into rod building through BB Custom Rods. What started as helping with prep work and handles eventually turned into his own growing custom rod business, focused heavily on California trout anglers.

Bill and Carlos discuss why trout fishin...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with Jim Schottenham of the American Museum of Fly Fishing, along with returning guest Bernie Schultz, about vintage fishing tackle, collecting, restoration, and why fishing history still matters to modern rod builders and anglers.

Jim shares how he became interested in early American reels, especially side mount reels, and how that passion led him to Lang’s Tackle Auction and later to his role as curator of the American Museum of Fly Fishing. He also gives listeners a look inside the museum’s collection, including hist...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with Aleks Maslov of Composite Ventures, North Fork Composites, Edge Rods, and Striker Rods about one of the biggest rod building conversations in years: Air Carbon Mesh. The episode digs into what Air Carbon Mesh is, where it came from, why it has created so much interest among rod builders, and whether it represents a major shift in how custom rods may be built moving forward.

Aleks explains how Air Carbon Mesh grew out of a much longer history of carbon fiber experimentation, including Gary...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with Mike McFarland of McFarland Rod Company about how he got started in fly fishing and rod building, how he eventually began designing and rolling his own blanks, and why slower, more responsive fly rods still matter in a market dominated by fast-action graphite.

Mike shares how growing up in central Pennsylvania and discovering trout rising in a local stream pushed him toward fly fishing, rod building, and eventually blank design. What started with building rods from catalog blanks turned into a much deeper pursuit...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with Bill Oyster of Oyster Bamboo about his experience taking the Oyster Bamboo Rodbuilding Class in Blue Ridge, Georgia, and what makes the week so memorable for rod builders, anglers, and first-time bamboo students alike.

Bill shares how years of hearing about the class finally led him and others to commit, and how the experience exceeded expectations from the moment it began. What stood out most was not just the chance to build a bamboo fly rod by hand, but the way Oyster and his...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with Captain John Irwin of Fly Right Charters about matching rods, reels, line, and technique into a complete fishing system for inshore, nearshore, and offshore fishing.

John shares how a lifetime of fishing, from freshwater and fly fishing as a kid to guiding full time in the Charleston area since 2002, shaped his approach to tackle selection and made versatility a core part of his business. As a guide who splits time between fly and conventional fishing, he brings a broad perspective to building outfits that...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with Tommy Farmer of Carolina Cast Pro about building true long-distance surf casting setups for big red drum—rods, reels, rigs, and the casting mechanics behind them.

Tommy shares how a 1996 trip to Cape Point, including landing a 45-inch drum and watching champion caster Mike Langston bomb a cast, sparked his path into competitive distance casting and surf fishing.

They break down the real-world system: why overhead (revolving-spool) reels outcast spinning when set up right, why Tommy prefers 20–25 lb mono with a 50–60 lb shock...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with master bamboo rod builder and engraver Bill Oyster of Oyster Bamboo Fly Rods about bamboo craftsmanship, building rods at the highest level, and the weeklong class in Blue Ridge, Georgia that fulfills Bill’s 30-year dream of making a split-cane fly rod.

Bill and Bill walk through how Oyster got his start—from fly fishing as an escape after bicycle racing and a life-changing accident, to teaching himself bamboo rodmaking from books, building his first 7-foot 3/4-weight, and eventually turning a surprise wave of earl...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with David Boyle of ThreadCentral about what’s new at ICRBE 2026 under new ownership and why the EXPO remains the can’t-miss event in custom rod building.

Bill and David break down the expanded show footprint with more floor space, two exhibit halls, dedicated seminar areas, and two Learning Center spaces designed for hands-on demos and better learning.

They also cover the weekend logistics—dates, hours, tickets (including online pre-purchase for faster entry), the RodMaker subscriber reception Saturday night, and a stacked vendor lineup...

In this episode of the Mastering Rod Building Podcast, Bill Falconer talks with Kevin Brotz of Get Bit Outdoors about new rod-building innovations—especially the Next Level and Halftime finishes—and why stability, clarity, and reduced yellowing matter.

Bill shares his firsthand experience building a full rod in one day using Halftime, and the two cover practical application tips for smoother finish results. Kevin also introduces Lockdown paste for tough, flexible bonds (great for demanding builds like slow-pitch jigging), plus new Get Bit products like a 20-inch wrapper bed extension and beginner-friendly R&R kits.

They...

In this episode, Bassmaster Elite Series angler Beau Browning joins us to break down everything anglers need to know about crankbait rods, from choosing the right rod blank to customizing the perfect setup. Beau shares his pro-level insights on the best rod specifications for crankbaits, including action, power, line weight, lure weight, tip taper, and rod weight. We also dive into handle design, including reel seats, rear grips, fore grips, and butt caps, and explore which guide train layouts perform best for crankbait fishing.

For anglers interested in building custom crankbait rods, Beau explains thread selection, epoxy...

In this episode of the Mastering Rod Building Podcast, host Bill Falconer sits down with Bassmaster Classic champion Easton Fothergill to dive deep into advanced bass fishing strategies.

Easton shares expert insights on drop shot rods, essential gear setups, finesse techniques, and real-world tournament experiences, including his recent run at the Skeeter Saltwater Redfish Series.

Discover pro tips on choosing the right drop shot rig, fishing structure like docks, grass, and heavy cover, and how these tactics help anglers succeed at the highest level.

Easton also talks about his journey after winning the...

In this episode, we sit down with legendary rod builder and educator Todd Vivian, a driving force in the world of custom fishing rod building, rod-building innovation, and craft preservation.

Todd shares how he got started in the industry, the early challenges that shaped his skills, and the moment he realized rod building would become his life’s work. He opens up about his creative process—from design concept to finished custom rod—and discusses the philosophies behind his signature style, known for its balance, precision, and durability.

Todd also reflects on key milestones in his ca...

Join host Bill Falconer on the Mastering Rod Building Podcast as he welcomes Nikki Paschen, renowned Gyotaku (Japanese fish printing) artist, ceramic specialist, and owner of Nautical Paschens, along with her collaborator Jen Cox. Dive into the vibrant world of Gyotaku fish printing on the Gulf Coast as Nikki and Jen share their journey from yacht detailing to creating stunning fishing art, apparel, and fishing memorabilia for anglers and boaters. Hear unique stories behind printing rare species like blue marlin and lionfish, discover tips for starting your own fish print art, and learn how the fishing community at Zeke's...

On this episode of the Mastering Rod Building Podcast, we sit down with AFTCO's Robby Gant to explore the deep history of one of fishing's most iconic brands.

We trace AFTCO’s journey from its groundbreaking origins in rod components, discussing what made their roller guides revolutionary, to its evolution into a full-fledged fishing lifestyle brand.

Robby shares the story behind their iconic fishing shorts and how the company balanced hardware innovation with technical apparel. This conversation also takes a deep dive into AFTCO's core identity of advocacy, detailing their 10% Pledge to Protect & Conserve, their fi...

Join host Bill Falconer as he welcomes Andrew Tsui, founder of the Ike Jime Federation, for an in-depth discussion on Ike Jime and Shike Jime—revolutionary fish care techniques that elevate seafood quality and ensure humane harvesting.

Discover the science behind rigor mortis, the impact of proper fish handling on flavor and safety, and practical tips for anglers looking to improve their catch.

Learn how these methods, recognized by top chefs and fisheries experts, can transform your fishing experience and seafood preparation.

This episode covers sustainable fishing practices, seafood aging, and the essential to...

In this episode of Mastering Rod Building, host Bill Falconer sits down with renowned craftsman Mark Blaum for an in-depth exploration of artistry, innovation, and tradition in custom rod building. Broadcasting from the heart of the rod building community, Bill and Mark trace Mark’s evolution from a passionate woodworker and pen turner to a world-class creator of segmented wood handles—pieces that have captivated and inspired builders across the country.

Listeners will discover the story behind Mark’s signature techniques, including the origins of his segmented turning, the challenges of sourcing and preparing unique woods, and the in...

In this episode of Mastering Rod Building, host Bill Falconer welcomes Steve and Joe Haywood—the father-son team behind HFF Custom Rods—for a special look at family legacy, innovation, and the future of custom rod building. Broadcasting from their Michigan showroom, Bill, Steve, and Joe trace the Haywood family’s journey from consulting careers to building one of the fastest-growing, most community-focused rod shops in the Midwest.

Listeners will hear the story behind the HFF name, the pivotal role of mentorship and family in their business, and how the Haywoods have embraced new technology—like 3D printing...

In this episode of Mastering Rod Building, host Bill Falconer welcomes two pivotal guests: Roger Seiders, the legendary founder of Flex Coat, and Brooke Oliva, president of Foundation Outdoor Group—the new stewards of the iconic brand. After nearly five decades at the helm, Roger reflects on Flex Coat’s origins, its impact on the rod building community, and the personal journey that led to this major transition.

Brooke Oliva shares how Foundation Outdoor Group came to acquire Flex Coat, what drew them to the brand, and their commitment to preserving the trusted formulas and equipment that have...

This week on the show, we go Inside the Blank. We’ve assembled a powerhouse panel with three of the leading minds in rod development—Rob Jenkins, Benny Ortiz, and Jorge Polo—to talk about the complex engineering behind slow pitch rods. They pull back the curtain on modern blank design, revealing why the blank itself, not the components, is the true heart of slow pitch performance.

From the core concepts of recoil and sensitivity to the intricate material science of carbon fiber and advanced resin systems, this discussion covers it all. The guys share the inside story b...

This week on the show, we’re joined by Todd Vivian, a respected leader in rod design and innovation, to talk all things travel rods. With more anglers looking for gear that can go anywhere without sacrificing performance, travel rods are having a serious moment—and Todd breaks down why.

From the rise in demand to the engineering behind a great multi-piece rod, we explore how these rods are designed, what sets high-quality models apart, and how even custom builders can get the most out of their blanks. Todd also shares tips for buyers, insights into the late...

In this episode of Mastering Rod Building, host Bill Falconer is joined by Tom Kirkman, founder of the International Custom Rod Building Exposition (ICRBE), and David Boyle, who will be taking over ownership and management of the event beginning in 2026. After more than two decades of organizing the world’s largest custom rod building expo, Tom reflects on the growth, impact, and enduring appeal of ICRBE—from its February timing to its central location in Winston-Salem, North Carolina.

David Boyle, known for his expertise in Visual Weave and project management, shares his vision for the future of the...

In this episode of the Mastering Rod Building Podcast, host Bill Falconer sits down with Steve Long, Assistant Director of the Outdoor Scholars Program at the University of Montevallo. They explore how the program has rapidly grown into a national model for developing the next generation of outdoor professionals, thanks in part to its top-tier bass fishing team and commitment to career readiness.

Steve and Bill reflect on success stories from program alumni—including one who now leads marketing at Bill’s own company—and discuss how the program blends academic excellence with real-world outdoor experiences. Whether you're...

In this episode of the Mastering Rod Building Podcast, host Bill Falconer sits down with Bill Batson of Batson Enterprises for a wide-ranging discussion on the evolving landscape of custom rod building. The focus is on Batson’s recent launch of 25 new rod blank models, with standout additions like multi-piece travel rods and extended-length jigging blanks that cater to the growing demands of modern anglers. These new offerings reflect Batson’s ongoing commitment to versatility, performance, and accessibility—key traits as fishing styles diversify and travel becomes more central to the sport.

The conversation also dives into the ro...

In this episode of the Mastering Rod Building Podcast, host Bill Falconer is joined by veteran custom rod builder and retired mechanical engineer Mick Danek. With 69 years of rod building experience and six patents from his automotive career, Danek brings a unique perspective to the science of blank performance.

The conversation focuses on True Natural Frequency (TNF)—a dynamic measurement of a rod’s recovery speed from deflection. Unlike the Common Sense System (CCS), which offers static measurements, TNF gives builders an objective method to evaluate rod performance and sensitivity. Bill and Mick explain how TNF can be m...

In this episode of Mastering Rod Building, host Bill Falconer sits down with Casey Portier, owner of Voodoo Custom Rods, to trace his journey from frustrated angler to custom rod builder and successful retailer. Casey shares how a disappointing rod purchase sparked his interest in building his own, eventually leading to the creation of Voodoo Rods—a business now known not just for its custom builds but also for its curated inventory of high-end Japanese components like Matagi and Just Ace. The conversation explores the evolution of Voodoo Rods from a boutique operation into a growing online retailer, the im...

In this heartfelt episode of Mastering Rod Building, host Bill Falconer welcomes longtime rod building veterans Bob McKamy, Buzz Butters, and Todd Vivian to celebrate the life and legacy of Curt Baker, a beloved figure in the rod building community. The conversation is filled with personal stories and memories that highlight Curt’s deep commitment to education, his patient and generous spirit, and his pivotal role in founding the Sun Coast Rod Crafters. The guests also discuss the recent dedication of the Foundation Outdoor Group’s education center in Curt’s honor, a tribute to his lasting influence. Through touchi...

In this episode of Mastering Rod Building, host Bill Falconer sits down with Carl Schmidt from Fisherman's Landing in San Diego to explore the rich sport fishing culture of Southern California. Carl shares the history of Fisherman’s Landing and its reputation for pioneering long-range trips, including an upcoming four-day adventure aboard the Pacific Queen, sponsored by Angler’s Resource. The conversation dives into the techniques and tools used in targeting prized species like bluefin and yellowtail tuna, as well as the landing’s cutting-edge practices in live bait handling and fish care. Carl also offers a look ahead to the...

In this episode of Mastering Rod Building, host Bill Falconer sits down with Mike Lum, the director of fundraising for Friends of Rollo and Captain Rollo's Kids at Sea, a non-profit organization dedicated to giving underprivileged children their first ocean fishing experience. Mike discusses the origins of the charity, which was founded in 1999, and its remarkable success in taking over 150,000 kids fishing, many of whom are introduced to the ocean for the very first time. The conversation explores the life-changing impact these trips have, fostering an appreciation for the ocean and potentially sparking a lifelong interest in angling and...

In this episode of Mastering Rod Building, host Bill Falconer previews an exciting upcoming rod-building event in Alabama, highlighting the key presenters, vendors, and the amenities that attendees can look forward to.

The conversation then shifts to an insightful interview with Dylan Weir and Blaine Kinney of Coastal Worldwide, expert land-based shark fishing guides on the northern Gulf Coast. Dylan and Blaine share their extensive experience in shark angling, offering valuable insights on responsible practices and recounting some of their most memorable catches, including great white sharks. The episode dives into their preferred tackle setups, including rods...

In this episode of Mastering Rod Building, host Bill Falconer welcomes Tom and Caroline Lewis, founders of the Kids Can Fish foundation. Caroline, with her father Tom’s support, created the foundation to introduce children and young women to the joys of fishing and the outdoors.

They discuss their mission to break down barriers to fishing by offering free, fully equipped camps and share inspiring stories, including a young angler with disabilities winning a tournament and another discovering a passion for fishing at a Kids Can Fish camp. The episode also highlights their major fundraising event, the Ru...

Host Bill Falconer is joined by Bill DePriest and Mike Bohn to discuss the upcoming Pacific Coast Sportfishing Show in Costa Mesa, CA. Taking place March 6-9, 2025, at the Orange County Fair & Event Center, this massive event spans eight buildings and features over 600 exhibitors, including top tackle brands, custom bait makers, boat manufacturers, and more.

Beyond the general sportfishing focus, the show also boasts a strong rod-building presence, with major names like Fuji, Batson, and Foundation Outdoor Group attending. The event features rod-building seminars, live demonstrations, and a rod-building contest supporting Warriors on the Water. Attendees can meet top c...

In this episode of Mastering Rod Building, host Bill Falconer welcomes one of the hottest names in professional angling, 2025 Elite Series angler Easton Fothergill. Easton’s rapid rise in the fishing world—from high school tournaments in Grand Rapids, Minnesota, to dominating the Opens with two wins and an Angler of the Year title—has positioned him as a top contender on the Elite Series.

They dive deep into forward-facing sonar, discussing its evolution, impact on bass behavior, and how it's revolutionized modern tournament fishing. Easton shares his approach to rod setups, including the importance of customization, rod le...

Join host Bill Falconer on the Mastering Rod Building Podcast for a deep dive into precision trolling—a technique designed to target fish at exact depths. Inspired by listener interest, Bill invites expert Tom Kirkman, founder of TK Rods and editor of RodMaker Magazine, to break down the essentials of precision trolling. Learn how anglers in the Great Lakes region use specialized rods, crankbaits, and depth control strategies to optimize catches, and why rod speed, spiral wraps, and line counter reels are crucial for success. Tom also shares an invaluable pro tip: swapping out treble hooks for circle hooks to...