The Big Fly Rod Popper Build (Step By Step)

[BilletHead]

This is going to be picture heavy so please bear with me. This will be more easy on my pea sized brain. This will be a guide and everyone will tweak their building process, less painting, more painting power tools etc. These poppers are pretty good sized but throw well with an eight weight. Adjust size to fit your needs.

I start by picking out my balsa. What I get is from hobby lobby and it is a bulk pack that has various sizes. I table saw the larger blocks down to about 3/4 to 7/8's sticks. I have a small miter box and saw to make this better. Angle in the ends to 67.5 degrees. Miter box has a slot for that,

I will be making three types of baits. General popper with a 2/0 hook and two with a wire form. One will have a prop blade and one without. Here are the layouts. Mark to length a bit long and do the prop one a bit shorter for the blade.

Before cutting to length use a dremel tool to cup the face. You can skip this step for a flat faced popper. Then cut to length,

The wire forms I use are for jigging spoons. Got a bag of a hundred at Bass Pro. To keep them in line in the popper block I cut a section, super glue and wrap on my vice,

Slot your popper block. I use my tiny miter saw. Keep the hook/wire slot to the bottom of your blank. Squirt in super glue and wire or hook,

You can just let it set up and putty the open slot but I have found a better solution. Clamp that baby! Have some small plastic clamps and I squirt in more upper glue and squeeze it shut. You will sometimes squash the balsa on the sides but no problem it will be carved away,

Try to put the clamps on the bottom corners and let it dry. When dry declamp and this is what you should have,

Got to let my fingers rest before more,

BilletHead

[ness]

This is gonna be good!

Don't leave us hanging, bro!

[Wayne SW/MO]

Looking great.

[BilletHead]

Ready for more are we Ness?

Time to hog off some wood! OK take you block and a knife. Disclaimer don't cut yourselves please. I use a el cheapo harbor freight special. Price wise it is cheap and comes with extra blades,

Work the front of the popper taking off the sides slowly. Take this from me you can't put more wood on once it is gone leave plenty of wood on the face rim.

Do the same to the rear end and make a slight taper front to back. Again don't take too much slow down young apprentice,

Work some more but not too much wood as sanding will do wonders. Before sanding this is what you should see.

Use 220 grit and sand to final desired shape. Again even 220 grit will go fast on balsa. No two will ever be shaped exactly the same. Remember you are making a custom bait. After the 220 I go with 400,

Now you could skip this step but I advise no to. Coat entire popper with super glue, front face too. I use a toothpick. The glue will penetrate the wood and harden the whole thing. Believe me this is worth the trouble. Moisture helps cure the super glue. On these humid days I set these outside on the porch to cure,

Sand one more time with the 400 grit paper. Painting will be next,

BilletHead

[BilletHead]

Ready to get creative and paint? Again this is all up to what you want in a paint job. Heck an all white or all black will catch fish but we want eye candy, well I do anyway. I know some of you on here like yellow shades for bass. It's all up to you. We won't get too wild here just a basic shad/baitfish pattern. Get your self some craft paint, acrylic again el cheapo is your friend. We will use white as our base coat. Paint your popper,

I sand again when this coat is dry and repaint. This stuff dries fast. Now to making a pattern on the popper back. Rob your kids of there butterfly net or go to hobby lobby and buy some netting in the fabric department. Cut it up in a smaller size and wrap your popper. Sometimes I rubber glove up and just hold the thing in my hands,

I then use some gray primer and just give it a dusting. Not too heavy just a mist. Less is more. Take the thing not moving the netting and blow on it to help dry. The thin coat will dry in seconds, then release the net,

Roll it over and give it some gill red or blood on the nose and bottom. Remember just a mist,

This is what it will look like,

If you choose to do a bit more painting I stipple/dot in every scale,

Give it some eyes too. Again just dots of various sizes. Black, white and then another dot of black. Eyes done,

When dry we will epoxy,

BilletHead

[BilletHead]

Where are you at Ness? Take a long lunch break?

Epoxy time. I use two ton in the side by side tube. Devcon is a good brand just make sure each side of the mix is the clear type. You can squeeze out just what you want. I have done one at a time to four. Mix what you want and get some, EL CHEAPO little brushes. Going to throw them away after each use. I get one of those kid friendly 100 packs. Coat your popper all over. You got time to work with the two ton so don't hurry.

Put it on the drying wheel,

If you are doing more than one get the others on there too,

While they are drying we will do some tails for two of these on the next installment,

BilletHead

[ness]

Hah! I'm here -- I was trying to eat pizza and read this thread on my phone (hint: not worth it). Now I'm back at 'work'. Looking good Marty.

I really love what the epoxy does to these poppers. Puts a nice, smooth, hard, glossy coat on them and makes them a lot tougher.

I really like your stippling too -- I can't seem to get mine that nice.

[Flysmallie]

You're doing it all wrong. That's why I wanted to see your SBS.

I always form the body before I cut the channel for the the hook or shank. Like your way better.

And I never coat the balsa in super glue. Lot of people do and it definitely toughens them up but I need to be able to sand a smoother base for the thin finishes I'm using. Well I probably don't "need" to but I personally have to. I don't like sanding the super glue so I just use spackling instead. Fills all the gaps and imperfections, dries fast, sands easy. Makes a huge mess.

I found some small Popsicle style sticks for mixing and applying epoxy. Also use toothpicks when I need just a little in a small area. It doesn't really matter what you use as long as you can get it on there somewhat even. The drying wheel will take care of the rest.

The stippling on each scale is badass. I'm stealing that part for sure.

Nice job Marty.

[BilletHead]

Well welcome back Ness, Yes once the finish on they pop to life.

Lay off the caffeine and pizza it will steady you down Actually I have days I can do stippling and today I was shaking badly. Got it done though. For the wire formed poppers I dressed up a # 4 treble. Between the three hooks I tie in strands of crystal flash and a saltwater hackle. Again you would do as you please. Single hook maybe? I know that the fish I am dealing with the treble hook is the bomb.

Here are the finished poppers. One built with a single 2/0 popper hook. Dressed with some flash, marabou and hackle. Two built with the wire forms. One with a prop and one without. These are pretty tough. I learned that if you hit a rock right hard they will chip. Now to a giveaway. Winner of a drawing will get the popper of their choice. All I ask is that you use the darned thing. Don't let it sit on a shelf to study, throw it. I have Ness and Wayne on my list. So sound off and let me know if you want a chance. We will let this go until Friday night at Midnight for the cut off. I will Phil to draw. I trust him but am not too sure about the rest of you all

BilletHead

[BilletHead]

No, no ,no Ronnie you are doing it wrong. You are on my list to smarty pants

BilletHead

And another thing. Popsicle sticks you are more EL CHEAPO than I am!