Pcray,
I not really ahead of anyone, I'm just a tinkerer, always looking for a better way. I wrote these instructions for someone and saved a copy. It is very detailed and looks VERY complicated, but it actually takes me 20-30 minutes at most to make a leader. Here goes........good luck:
How to Make Mono Furled Leaders (without a jig):
You can use any type of mono. I choose the regular mono that one would use on a spinning outfit such as Trilene. I find Trilene more limp than say Stren or some of the others, a good attribute for a leader butt IMO. For making a leader for a 4 or 5wt line, I use 6lb test mono, which is equal to 2X diameter in fly-fishing terms.
For making a 5’ (60” leader) with 6lb/ 2X mono I use the following taper:
18” (8 strands) > 16” (6 strands) > 14” (4 strands) > 12” (2 strands) = 60”
Stated another way, to build such a taper, here are the lengths of the four doubled segments needed to be furled:
60” ___________________________________________
48” _________________________________
34” ______________________
18” ____________
Peel off enough mono to make the 60” segment first. Since the line is furled (twisted together) you need to double the 60” equaling 120”, and add another 20” for waste and making the loops, which equals 140” total.
Take the 140” piece of mono and match the ends to double it in half. Go to the end that now has a loop formed and hold the mono on each side of the loop between your fingers. Rotate each piece of mono IN THE SAME DIRECTION and it will furl (twist) together and form a single line. This is best done over the back of a chair to keep the line separated and keep it from twisting together. After I furl down the entire length, I put an overhand knot on the end to hold it together. You now have the first of 4 segments completed. Put this segment aside for now.
Go the next longest segment, 48”. Double that length (96”) and add 14” for waste, totaling 110”. Follow the same procedure as the first segment. Furl the entire length, knot it at the end, and put it aside.
Now furl the 34” segment (78” of mono) and the 18” segment (50” of mono)
You now have four segments of furled mono in different lengths. Take the two longest segments, the 140” and 110” ones, and join them together with a overhand knot. Furl (twist) those two segments together IN THE OPPOSITE DIRECTION from the way you furled the first time. When you twist in the opposite direction, it tightens the furl, rather than loosening it. Check to make sure you are tightening the furl.
Now follow the same procedure for segment 3 (78”) and segment 4 (50”). You are now left with two segments. Knot them on the end and furl them together again IN THE OPPOSITE DIRECTION as during the last procedure. This actually would be in the same direction as when you started. Again, check to make sure you are tightening the furl.
You now have a single furled leader that is tapered. Go to the butt (thicker) end and whip- finish a loop in it. I use my fly tying bobbin with 6/0 tying thread on it and wrap about ¾” of thread for the whip finish. You can use a bobbin threader or a loop of mono to pull through the last 10 wraps of thread to secure the whip finish, just like in wrapping a guide when rod building.
After the loop is made, lay out the leader on a tape measure and put a little masking tape on the loop to hold it in place. The 1/8” masking tape used in rod building is ideal for this. Measure down to 18” from the loop and put a thin strip of masking tape on that mark. This will be the end of your first segment. Mark the next segment with a thin strip of masking tape at 34” and the next at 48”. Now at the thinnest end of the leader, whip finish a loop ending at the 60” mark.
Now whip finish the middle segments at the masking tape mark. I’m fly tier and a rod builder, so the procedure is second nature for me. I use my fly tying bobbin with 6/0 thread and start the thread on the leader just as I would on a fly hook. After starting the thread, let the bobbin hang down and turn the leader to wrap it, just as I would when wrapping guides on a rod. Every 6 or 8 turns I use my fingernail to pack the threads together. Before making the last 10 or so wraps I insert a bobbin threader, you can also use a loop of mono, cut the thread leaving a long tag end, insert it through the loop or the bobbin threader, and pull through the tag end through the wraps to lock them in. I try to keep the thread on the completed whip finish about ¾” long. Go to the next section and continue to whip-finish all of segments in the same way.
I now stretch out the leader and make sure all the furling is tight. If it is, I now remove the masking tape and trim the tag end next to the thread wraps. I put a dab of “ZAP-A-GAP” on the thread to secure all the mono together. When that dries, I coat all the thread with a little bit of “Knot Sense” to seal them. This also allows the leader and loops to slide through the guides easily.
For this 5’ 4/5x leader, I typically attach 18” of 3x loop-to-loop, next I tie in 18” of 4x with a blood or surgeons knot, and add a 24” 5x tippet. This will give you 10’ 5x finished leader. You can experiment with different tapers at the end for better fly turnover or for getting more slack in your leader if that’s what you’re after. For slack casts I use the George Harvey formulas to finish the end of the leader and the tippet.
It looks like a long and complex project. But after doing it a couple of times, I find that it does not take much longer than measuring, cutting, and tying all those blood knots on a knotted leader. I can make a furled leader like the one described above in about 20 minutes.
Here are some things I have found:
You can use any type of mono for your furled leader, or even flouro if you want them to sink. You can also use Stren Gold mono or other similar brands for a hi-vis leader butt. I most often use regular mono (Trilene), 4 lb for lighter lines (2-3 wt), 6lb for mid weight (4-5wt), and 8 pound for my heavy trout, steelhead or bass line (6-8wt). As a guide, 6lb Trilene = 2x diameter. I like the Trilene brand because it is limper than most other mono.
I tie my furled leader butts as short as 3.5' long for my 6/7' small stream trout rod, all the way up to 7' long to build a delicate taper out to a 15' finished leader length. Five feet is the average for my 9' rod which tapers out well to a 10' or 11' finished leader.
You can use white thread, which will “disappear” when it’s coated, or you can use fluorescent colored thread, which can double as a strike indicator. I usually use white thread and work a dab of orange “Strike Putty” into the leader butt for visibility. It shows up well in the water, and can be removed if desired.
I like to use a paste type floatant and work it into the furled leader butt. It will float all day and mend like a dream when treated with floatant.
Give it a try. Good luck.