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Jan 12, 2022

Creating Tandem Fly Boxes!

Creating Tandem Fly Boxes!

Blogs are back! After some time we will be continuing to add to our blog this time with more featured guests! Our first feature is Elliot from Tandem Fly Company. I have had the pleasure of getting to know Elliot over the last two years and we've talked about everything from manufacturing to marketing his products. This blog will hopefully give you an inside feel to how he brought this product to life and what makes it a fantastic box for many applications.

Enjoy!

From Idea to Reality:  Developing a Fly Fishing Product

"My name is Elliot and I’m one of the guys behind Tandem Fly Company’s Dropper Rig Box.  It’s a simple solution to storing pre-tied rigs in a fly box.  We’re relatively new to the scene and Spawn has been carrying our product for the last year or so.  As manufacturers in the same industry, Josh and I have shared a connection and a passion for talking shop.  It’s been awesome. 

We thought it would be cool to give you a look at Tandem’s  journey and some of the challenges and considerations it took to develop the Dropper Rig Box.  Just like us, Spawn has developed and manufactured their own products like jig shanks, heads, football beads, simi-seal dubbing, etc.  Manufacturing consistent, quality products is a ton of work and Spawn excels at it.  Spawn’s products are not generic products with a brand slapped on them, they were dreamed up and personally developed.  The fly fishing industry is a tight-knit community of small businesses with real people behind the scenes.  As small businesses, there’s no budget for outsourcing and we need to take on everything from production, assembly, order fulfillment, advertising, social media, bookkeeping, you name it.  We as consumers rarely get to see this side of things.  Suffice it to say, we take pride in our businesses and their products.  Here’s a look at how one of those products came to be:

 

Dropper rig storage: a problem in need of a better solution

Everyone hates rigging up and tying knots.  It wastes valuable time that should be spent fishing.  Growing up in Colorado and frequenting many technical tailwaters, I have had many frustrating days spent matching hatches and endlessly re-rigging flies.  That’s why I wanted to create the Dropper Rig Box.  Yes, there are other solutions to storing tandem rigs, but often that means adding more gear to your pack.  As a wade-fisherman and a minimalist, I say no to that.  Everyone carries a flybox, why not configure the leaf to hold rigs as well?  Simple.

 Made in USA

From the beginning, we have chosen to source close to home.  Working with domestic suppliers supports local businesses and safe working conditions.  It also gives greater control over processes, allows for quick troubleshooting, easier communication, and quicker delivery.  Most importantly, domestic manufacturing gives us the ability to constantly improve and produce the very best product possible.

Materials

Our product needed high quality materials.  We tested a ton of different foams to find one with the dense, resilient qualities that would hold flies secure.  Holding that foam in place required a strong adhesive tape capable of withstanding wide temperature ranges (in case you ever leave the box on the dash to bake in the sun).  For the plastic, shatter-resistant polycarbonate was chosen for durability and longevity.  See for yourself...

*video*

Design Considerations

Proper functionality took priority over cost, no skimping.  Our dropper page is a great example.  It is made from multiple components even though it would have been cheaper to create from a single foam sheet.  This was done because a single slit-foam sheet is too flimsy to keep flies secure, it needs a rigid core to stiffen things up.  Additionally, we went to great pains to ensure that our page would leave rigs kink-free and ready to use.  We constructed the page in a way that the tippet would not contact any foam adhesive (leaving gunk) or the inner plastic sheet (leaving kinks). 

Having the ideal attachment for the dropper page was also key, we needed something simple and secure.  Many iterations of magnetic and press-fit attachments were tested, but none were reliable.  They would often fall out of the box while wrapping a rig, or if accidentally bumped.  In the end, a mechanical snap-clip attachment was the best way to go.

Prototyping

3D printing is an amazingly fast and cheap way to do this.  You don’t need to spend thousands on a 3D printer.  In fact, there are many online 3D printing services available.  Just upload a design file, choose your material, and order parts.  Next add some craft foam, double-sided tape, steel wire, and you’ve got a flybox!

 

Patenting the Idea    

It’s important to protect an invention from copycats.  Unfortunately, lawyers are expensive and patent law isn't a DIY thing.  Luckily, there are programs out there that level the playing field by offering pro bono (free) patent prosecution.  We worked with ProBoPat, an organization in the mountain west that connects inventors with patent practitioners for patent preparation and prosecution.  We got a patent.  Even if we didn't, knowing the IP regarding other products in the industry is a must.  You don’t wanna step on anyone’s toes and end up with a lawsuit. 

Manufacturing

Manufacturers didn’t exactly drool over us, it takes them a significant investment in time and effort and they want to see it pay off.  Luckily, we found a local injection molder who saw our vision and decided to take a chance on us.  We then invested some serious money to get our molds tooled.  Tooling a mold out of hardened steel is an intricate, time-consuming process.  However, once complete, a mold can last for hundreds of thousands, if not millions of parts.  Here’s our smallest mold in action: 

Foam

This was a major headache.  We went through multiple suppliers and scrapped more material than we’d have liked before finding someone capable of providing consistent quality and thickness.   Even finding a die-maker who was able to create the intricate design of our slit foam inserts was a challenge.  We talked with dozens of manufacturers before we found a great partner out of Pennsylvania who would take on the challenge.  The results speak for themselves.

 

 

Lots of Learning

We're not engineers, we’re just regular people.  The learning curve has been steep.  I didn’t know CAD in the beginning.  In fact, the first prototypes were made using a free online program called Tinkercad (for kids).  Designing for manufacturability, knowledge of materials, and gaining experience working with different manufacturing industries took countless hours and each had their own challenges.  Along the way, I'd like to think we earned honorary industrial design degrees.

 

A Long Time Coming 

It took over three years until we launched the product.  Yes, it took a while.  If you look up bootstrapping in the dictionary, our pictures are there.  All I can say is that we’ve put in countless nights, weekends, and everything in between. 

 

We’re extremely proud of the Dropper Rig Box.  It turned out great, it’s useful, unique, and made in the USA.  We hope you like it too."

 

-We hope you enjoyed this inside look at the Tandem Fly Box and everything that goes into brining a product to life in the fly fishing industry. Countless hours go into creation and we are so happy to be a small part of the Tandem Fly Co Journey! Order your box today! CLICK HERE!

 

- Josh Phillips

 

 

 

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Aug 27, 2021

Fall Fishing

Fall Fishing
    Do you have a favorite fishing season? Autumn happens to be mine. Not only are the temps cooler and the colors of deciduous trees on full display, but most importantly the fish are more than excited to take a fly. I’d like to share some simple steps you can take to ensure some of the best fishing days you may have all year. More properly they can be thought of as courtesy reminders for things you probably know and still decide to skip. I’m guilty myself.
  
     One of the first things I like to do is replace any leaders that are in use or that sat in the fly bag or car during the summer. I’ve lived in Arizona long enough to tell you leader material does not last after it’s been baked in a car. Sun damage does the same, so remove any doubtful leaders. This extends to tippet material as well. The time to save a few cents will not be when a trophy brown takes your old 3X tippet into his labyrinth of trees and rocks. Your chances of catching a large trout are higher in the fall because of fish fattening for winter and, for some, before they spawn. Fish of all sizes are nearer the reachable water and looking for food. There is no replacement for replacement.

     Fly selection takes on more importance in the fall if you’re fishing famous tail waters or heavily fished areas. Typically the water will be lower in the streams and rivers where technical fishing is the norm already. This means tiny tippets and accurate bug representation and presentation. This all gets dumped out of the fly box as soon as we consider the brown trout claiming territory and disregarding all thoughts about pesky fly tossers. They are more in the mood to kill your streamer than they are to hide in the shadows. They are looking for trouble and I can’t think of a better time to introduce a newbie to the sport. Angry fish who only become more excited with plopped flies and erratic line strips. Win, win.

     This may register more with a certain age demographic than others, but its importance has equal value regardless of age. In the fall kids are returning to school, vacations are dwindling and snow birds are preparing to head for AZ or FL. This means less people on some of your favorite haunts. That’s great news for better fishing and the beauty only solitude can disclose. But there is a dark side as well. If you are injured or otherwise compromised there is less chance someone will notice. That’s one of a zillion reasons to fish with a buddy or at the very least let somebody know where and when you’ll be going. It’s an easy thing that gives you and those concerned some peace of mind. Peace of mind leads to better fishing which leads to peace of mind.

     In order for that mind to keep functioning whilst on the water it may be time to bust out the dome decorations. The wind, colder, drier air and sunlight are all making a claim to tour skin. Cover it and stay protected. When the sun dives down behind the mountains and you just had to fish the last pool you’ll be glad to have an extra hat and jacket for sure. Gloves can be great after your hands have been in the water all day. They’ll be warm from being in your pack and you’ll save a bunch of heat heading back to camp or your vehicle.

     An entire change of warm clothing is always a good thing to keep in a dry box for fall fishing. Toss it in the ride and if you fall in or get caught in a storm you’ll have some dry threads awaiting your return. Speaking of rides, depending on your geography and weather conditions the roads can become an issue faster than you might be able to adjust. Plan ahead. Keep your vehicle regularly maintained and stow some food and water for emergencies. A recharging device for your car battery or gadgets is an added bit of insurance that only needs to be used once to prove its worth.

     I’m so very grateful to all of you who read this and I sincerely hope that you find at least a tiny crumb of useful information. Fly fishing and fishing in general can be absolutely spectacular in the fall. But taking a deep breath before we lose focus in autumn’s beauty can make it that much more special. And remember, fish live in the water year round. Cooler air temps don’t make it any easier for them to breathe above the water, so leave them in the water as much as possible. Thanks for reading along and enjoy your fall fishing!

    

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Aug 19, 2021

Big Eyed Flashback Mysis Shrimp SBS

Big Eyed Flashback Mysis Shrimp SBS

     There is a certain satisfaction that comes from catching big fish on small flies: especially in a tailwater system. But to me there's just as much fun in finding the bruisers looking for something just a bit different, but without necessarily having to sling streamers. The Big Eyed Mysis has enough familiarity for recognition as well as some exaggerated triggers that can make all the difference to an undecided fish. This pattern is also a lot of fun on stillwater, but with the addition of weighted wire wraps or weighted eyes. Have fun tying this little fish catcher and remember tying flies is supposed to include having fun. Thanks for tying along and we'll look for you on the water!

Materials List:
Hook- Daiichi 1150 sz 12
Thread- UniThread 6/0 White
Antennae- Simi Seal Crystal
Eyes- Hareline Black Mono Nymph Eyes
Shellback- Thin Skin Fly Specks Clear/Black
Flash- Saltwater Flashabou Holographic Silver 
Ribbing Wire- Brassie Silver
Body- Simi Seal Crystal
Cement- Loon Hard Head
Step 1: Place the hook in the vise. The Daiichi 1150 has a larger hook gap that will accommodate a number of eyeball options. 
Step 2: Begin your thread on the hook shank and wrap down past the hook barb to a few wraps down the bend.
Step 3:  For the antennae we will tie in a sparse clump of Simi Seal by tying down the material in the middle of the clump and directly on top of the hook shank. Three secure wraps should suffice. 
Step 4:  Before we veil the material, take one thread wrap in front, (toward the hook eye) of the material to be pulled over. Once you've taken the thread wrap you can bring all the Simi Seal facing over the hook bend without losing any fibers. Tie this veiled clump down with a few strong thread wraps and trim the Simi Seal unevenly a length similar to the body length. 
Step 5:  Now we will tie in a strip of Thin Skin that is just wider than the hook eye. Take care to not twist the Thin Skin and to keep it on top of the hook shank and tied all the way back to our antennae tie in. 
Step 6: Leaving a space of roughly one hook eye we will place our eyes on top of the hook shank and securely tie down using figure of eight thread wraps. Leaving that bit of space will ensure an adequate amount of dubbing is in front of the eyes for a proper looking head.
Step 7: Top view after tying in Mono Eyes.
Step 8:  TIme for some bling. Tie in the Flashabou on top of the hook shank just like the Thin Skin. Tying in the flash after the eyes is an added bit of insurance when making sure there is ample area for the dubbing in front of the eyes. And the few extra figure of eight thread wraps it takes to get the flash all the way to the previous tie ins will only strengthen our eyes. 
Step 9:  Now we will tie in a piece of ribbing wire on the near side of the hook. This wire should be tied all the way up to the eye, but not past. Bring your thread up to the hook eye once completed. 
Step 10: For the body we will need our dubbing noodle to be very sparse and very tightly twisted. We will dub from the eye of the hook to the eyes, figure eight a couple wraps around the eye and head and back to the hook eye. This requires a dubbing noodle approximately 5 inches in length. Take your time and apply dubbing as needed to just barely make it back to the hook eye. Be sure the ribbing wire stays in its original position as you dub the body and head.
Step 11: We can now bring our flash over the top of the dubbed body and tie down behind the hook eye with two secure thread wraps. While maintaining thread pressure pull the flash back over itself, tie down with two more thread wraps and trim the excess. Pulling back the flash in this manner will prevent it from slipping out of the thread wraps and also from shifting while we finish the fly.
Step 12: Pull the Thin Skin shellback over the flash and tie down with 3-4 solid thread wraps. As you trim the excess you can leave just a bit of material to emulate a tail. Cut a small V to add realism and to make access to the hook eye just a little easier when tying on the fly.
Step 13:  Now we will wrap our ribbing wire in 4 to 5 evenly spaced wraps to the hook eye. Tie down and trim the excess wire. Making sure you don't crowd the tail and hook eye make a neat thread collar, add two whip finishes and trim the thread. Cover the thread wraps with Loon Hard Head or cement of your choice. You are now prepared to catch some of those cynical fish who have seen one too many size 18s or just flat out put on a clinic the next time your buddies are tossing worms to sunfish. Thanks for tying along!
Step 14: Top view after wire rib.

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Aug 12, 2021

Fly Fishing Means Never Having to Say Goodbye

Fly Fishing Means Never Having to Say Goodbye
Fly Fishing Means Never Having to Say Goodbye


Chances are fairly good that there is a meal from last week you can no longer remember. Or maybe this morning you spent an extra minute or two looking for the car keys you just put down. But if I asked you where you learned to fish or first cast a fly there would undoubtedly be a small smile in your heart as the image came screaming to the front of your memory. Follow with me as I bid farewell to the water that has taught me so much, but like an old friend will happily cross my path many more times during this life.

My journey into fly fishing began with a camera. I was hired by a guide, DB, who owned a fly shop and built bamboo rods to take some photos of him fishing and his bamboo in action. I’d grown up a gear fisherman and had zero exposure to fly fishing. When we got to the Arizona stream to fish, my 600mm lens could almost reach the other bank. While I was still laughing and switching cameras, DB points to a small rock 20 feet upstream and says “I’m gonna catch one right there” and in one false cast tosses what to me looks like nothing at the end of more nothing to produce a small brown trout exactly in the spot he had said. My camera body and jaw were both still wide open as he released the fish and said, “Did ya catch that?”. My life was never going to be the same.

At the end of two photo sessions we had more photos than we needed. But without either one of us ever voicing it there was no question that we’d be on the stream again in a week’s time. The camera came along, but it was only sparsely used as I began to fumble with casting a fly and mending/tangling a fly line. Many fish were missed, but each one solidified an ever growing fascination. The fourth week we hit the stream with no cameras. And then the fly kit gets ordered. And books, materials, the urge to fish new water and all the normal progressions of a new addiction.

But one thing remained constant. We’d always find ourselves eventually going back to that little stretch of water that had become endearingly termed The Secret Spot and eventually shortened to The Spot. After years of visiting the familiar pools and bends you feel at ease simply for proximity as much as for the fishing. The place where the ghosts of laughter wait at the barbed wire crossing to remind you ALL waders will eventually leak. Or the lightning scarred Ponderosa Pine that houses the overzealous osprey who keep you honest in your ability to raise a timid fish. A new fly could work in 50 different destinations, but if it didn’t work at The Spot it wasn’t really worth tying.

As things typically look clearer in hindsight, it’s easier now to recognize the transition from home water to home waters. What had begun as a stretch of the river became learning the entire river to the lakes and other streams. You begin to realize The Spot includes old Lyle’s tackle shop and his selection of marabou a unique shade of sun-fade mixed with old nicotine stains. Or the new to fishing souls you encounter who can benefit from a few local flies that actually work. It includes mingling with what to me and many others were legends of tying and fishing, but outside the mountains might never be recognized.

Advance the clock and now there have been many different waters plied. Miles and states crossed off maps. There have been multiple species encountered in fresh and salt water. In what seems a whirlwind of life, Spawn Fly Fish began and years later it’s time for me to leave Arizona for the opportunity to work with Josh in our store in WA. The experience upcoming is more exciting than anything I’ve done. Not to mention the fishing! That will be a story for another time.

     But as I’m trying to pack and arrange moving plans my mind and heart are pulled back to The Spot. Some of that pull is the fact I won’t be able to see it before moving. But I think the greatest thing fly fishing has shared with me is the realization that everything I now do and will learn going forward with fishing, tying or living is going to carry the foundation shaped on those home waters. That includes the understanding that as long as I’m still applying the knowledge gleaned from The Spot, then it can always travel with me. It must. That’s a comfort that allows you to look and move forward. There is no way for me to undo what was instilled from that little stretch of water. It will forever be a fishing buddy that sits in the truck. If your fishing buddy was always in the truck you wouldn’t tell them goodbye, so... See you all soon in WA and thanks for helping me say Tight Lines to all my fishy friends in Arizona. A special thank you to DB. Cheers!

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