Thanks, Alacran. I will be a patient guy and wait for your demo.
I can see a routed channel in both halves of a ramrod, assuming you can either split the wood or saw it with a thin kerf saw.
Hmmmm. I wonder if we could get a 48" long 1/8" drill bit? Be about as easy as training a termite.
Sorry about taking so long to do post this. I will explain how I do it. I take a hickory board with the straightest grain I can find. of course it has to be long enough for the length ramrod I need. Anything over two inches wide will work. I joint the face of the board and get it perfectly straight. Then I joint both edges. I do this on Jointer. I suppose it can be done with hand planes if that is all you have.
Next step is to cut a groove on the center of both edges. I do this on the table saw. I have done it with a router. I like the table saw better. The groove needs to be about 5 thousands deeper than half the diameter of the rod. I like to use 5/32 diameter piano wire for rods 36 inches or shorter. For longer rods I use 1/8 stainless. If you use piano wire you need to heat the ends cherry red for about three inches or you will never be able to drill it for a cross pin.
Also the groove needs to be about 5 thousands wider than than the metal rod.
I then cut one of the grooved edges about 5/16 thick. I then degrease the metal rod and rough it up with a file or sangpaper. After that I clean it to get the metal dust off of it.
Before I glue it up I make sure there aren't any high spots on either groove. You can make a scraper from a short piece of the size metal rod you are using. I make sure it will work dry before I mix up any epoxy.
I have used Acraglass gel, I even did one with gorilla glue. Now I use a slow cure epoxy I get from K&G Knife Supplies.
I glue it all up and clamp it about 2 inches on center.
The epoxy I use was developed to attach golf club heads on shafts and has a 24 hour cure.
After it is cured I cut the lamination off on the table saw to a 1/2 to 7/16 overall depending on how thick the ramrod is going to be.
The picture is of a blank ready to be rounded.
If you look close you can see the seam. This one is 5/32 piano wire.
I will be prepping another one in the next few days and will take some more pictures.
As to why. I have rods that are 20 years old. I never worry about breaking them. I never have to take a range rod with me on a trail walk. I saw a guy at my first rendesvous with half a hickory rod stuck through his hand.
dnd roll