I have built a lot of fly rods [ well not do many ,] here is the problem , I have ordered some fly blanks from a name supplier , [ no name ] the tip size is like 4.1 or 4.2
these seem like an odd size to me , not the normal , what is the normal way of dealing with it , [CARBON rod] do you just get a size that will fit over, then fill with glue an thread ??
I don't want to sand it down to size , give me some direction , thanks for the in put , I think I have answered my own question , [ fill ] to the next size an use thread an glue ,

William Sidney
AK

You don't want to sand the tip. Get a 4.5 tip. It may be a slightly loose fit but no matter. I use 5 min. epoxy on tips but thermo tip glue works fine. When you wrap thread up against the tip tube and apply finish it will look right.

What John wrote; do not sand the blank tip to fit a smaller tip top.

If you had rather not make a tip top wrap and there is a noticeable gap between the blank and base of the tip top tube, a tiny bit of thread wrap finish epoxy, about an 1/8' wide or less, on the blank at the base of the tip top tube will form a ramp of sorts that makes any gap between the tip top tube and blank almost disappear.

If the tip top is slightly small, and close to fitting, and If the blank is painted or has a clear finish I just scrape the finish off the tip of the blank with a utility knife and install the tip top with hot melt tip top cement. Removing the finish from the tip will do alsolutely no harm. If you do not want to do this then use the next size larger tip top. I personally will not use epoxy to install a tip top, and that includes the 5 min stuff; in my opinion not worth the problems it may cause.
Norm

I just would use a size 4.5 tip and do a thread tip wrap and let the wrap extend down the rod as would be the normal case for a tip wrap when it is used.

If you find that you need more thickness, then in the area of the tip only, do a double thick wrap and then down to a single layer wrap for the rest of the tip wrap.

Easy to do, glues up nicely and you have the nice finished thread wrap look to the tip without having to do anything else.

Good luck

Thanks for all the info

William Sidney
AK

I have a set of really small drills and have drilled the tip top to fit.