O.K., Here We Go Again - a New Deep Fluking Reel Build

Leprechaun

Kind of a Big Deal - In My Mind Anyway
Staff member
First, a little background. I've been on the lookout for a low-pro bait caster to use with my Proteus H, on those days that are a might "nautical" out in the deep. I refuse to just give up and head into shallow waters on rougher trips, if I KNOW the fish are there. Its really just a matter of being able to present baits in a manner attractive to the fish, whilst dealing with such adverse conditions. This normally involves stepping up to 5 or 6oz bucktails, and in the event that even those do not hold bottom, then out come the B/S Rigs, with 8-10oz sinkers. That, along with the deployment of the drift sock usually does the trick, in my experience.

What is needed in this specific application is a compact low-profile bait caster, one that can "take it" when is comes to handling heavier bucktails and/or sinkered rigs. This is considerably more difficult to find than one would think.

After reviewing every new low-pro bait caster on the market, I could not find one that absolutely checked every box on my "must have" list. This one has a plastic side plate, that one doesn't offer an appropriately low gear ratio. On and on, with disqualifications of every current model. I was really considering pulling one of my round Abu customs out of semi-retirement. But then this reel happened.

Sometimes a deal comes forward that one cannot pass up. I am a BIG proponent of the last generation of the Daiwa Zillion bait casting series. Just super reels, from the aluminum frame and side plate, to the variety of gear ratios still available for swaps, to the overall construction and quality of components, they are just about as good as it gets in a palm-sized reel. They were never inexpensive, normally retailing in the $350-range for the more common versions; on up to $500+ for the more feature-laden and far more rare JDM (Japanese Domestic Market) Zillions.

I've been looking for one of two specific JDM versions, the Zillion 100H HLC and/or the Zillion 100H PE, for a VERY long time. Both were released to the Japanese market around 2008, and were available for a few seasons thereafter. Well, after years of religiously checking the various Japanese re-sellers of used tackle, as well as the Japanese and US-versions of Ebay, I FINALLY found an HLC in the condition I prefer, and for roughly the price I am crazy enough to pay. Right around $190 - which IMO is super fair. My new reel is truly mint - maybe one or two TINY flea bite-sized flaws in the finish. Believe me when I say this is like finding a freakin' needle in the proverbial haystack. Take a look:

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I don't know what it is about those Japanese FW bass fishers, they must literally throw their tackle around in the boat, as I have never seen such a clean HLC - most look like the former owner took a rasp file to them. Horrible condition reels, offered for $300-$400 all day long. Maybe someone else would pay that for a beat-up looking reel, but that ain't me.

So let me speak to what makes this reel special. First, its a Zillion. that right there says something. This is no cheapie Tatula or whatever Tatula-like reel was in the Daiwa line-up back then. This is/was nearly top of the Daiwa line, and you can feel it the first time you turn the handle.

In the case of the HLC, they took the base Zillion (as though the word "base" applies to such a reel), and added ABEC-5-rated corrosion-resistant bearings throughout, used a Steez aluminum drive shaft (the Steez IS the top of Daiwa's casting reel line), a CR (corrosion resistant) bearing on the level wind worm, a specific "Hyper Long Cast" spool that spins when you breath on it - which is in GREAT demand on the FW Bass fishing websites - I can easily sell just this spool for the $190 I paid for the entire reel if I so choose (Can you believe that? How crazy are these FW bass fanatics? Nothing like you and me! :p ). Also, a very specific mag-cast braking system, a unique at the time carbon-fiber handle with cork knobs, weight-saving cut-outs atop the aluminum frame, and finally, factory purple highlights in several fairly subtle locations. Subtle? Hah, well I'm gonna fix that "flaw," THAT'S for sure!

The HLC was a super hot seller for a low-production edition, but Daiwa never brought it to the US market. I guess they didn't think we enjoy using high-end stuff. They couldn't be more wrong - as the rarity of finding one in good condition attests. Anyone who owns a mint condition specimen hangs onto it.

What we're gonna do is to make it far more suitable for what I do - deep fluking with bucktails and B/S-Rigs carrying up to 10oz sinkers in deep water. To do this we will need a few mechanical upgrades, as well some extraneous blingy stuff to make it uniquely "Leppy." Look here:

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What we have clockwise is a set of purple aluminum screws, a purple aluminum spool tension nut, a shiny new nose plate, a Ray's Studio 100mm carbon-fiber curved handle with custom-installed Abu Toro grips (No small feat to make this happen - it took me a few hours of trial fitting, filing, and adjusting to make it perfect), a 4.9:1 ratio set of Zillion Crazy Cranker gears to replace the mint factory 6.3:1 gears, a set of sexy purple handle-securing hardware and lastly, a purple mag changer securing screw. The HLC was already a fully ounce lighter than a standard Zillion - and these upgrades should bring it down to the 7oz level - pretty darn good for such a solid reel.
 
Take a look at the difference in handles. The puny 80mm Japanese version should go hide in the corner, once the "Big Bully" 100mm Ray's Studio handle comes to town. Add in the Abu Toro knobs (in sexy purple) and there's no comparison. This handle alone completely transforms the way a small casting reel performs in h/d SW use, and is waaay more comfortable to to the hand:

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While doing up the handle it would be a crime to not upgrade the drag star as well. So I went with a Ray's Studio matching carbon fiber version - which besides being sooo much nicer to look at, really helps out when making fine drag adjustments whilst tied to a large flat one. No searching around with my thumb. Those long drag star arms are always right there, ready to help.

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This next seemingly insignificant "upgrade" was and always will be the toughest part of any Daiwa Zillion build up.

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Doesn't look like its anything more than a "can of corn" to do, right? Just screw it in, right? Wrong. Every single piece in Daiwa's magnetic braking system has to come out of the port side plate in order to get that purple screw in there. Not only are there at least 15 miniature/micro pieces that make up this system, but a few are also heavily magnetized - making proper re-assembly a nightmare to correctly accomplish. This includes, but is not limited to, hidden lock-tighted screws that defy one's efforts at extraction without stripping their heads, weird tiny securing plates holding other things together, and micro E-clips that seem to enjoy flying over one's shoulder on dis-assembly OR assembly. A real test of a tuner's skill. But it got done. Whew - all for a freakin' screw color change! :rolleyes:

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Take a look at how clean the interior of this 10 year old reel was on arrival. You just NEVER see this type of OCD-level upkeep. Its a rarity, to say the least.

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A tight shot of the light weight aluminum screws that replace the factory chrome-on-brass versions. These use a 2mm hex driver instead of a Phillips blade screw driver.

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Part 3

Now we're gettin' to the good stuff. In the next image the factory-original 6.3:1 gears are up top, with the replacement 4.9:1 gears directly below. Note that while the 6.3 set have a bit more diameter, just look how much more beefy the teeth of the 4.9 set are. No comparison in brute strength. Bigger is ALWAYS better in gear teeth. Daiwa knew that the users of the original 4.9:1 gears would be subjecting them to some heavy lifting, and so they designed-in the larger gear tooth surfaces. That's a good piece of thinking, indeed.

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No comparison - and I speak from experience here. I've had a set of these 4.9 gears in my other Zillion for three seasons of hard use. No issues.

The next shots show an area of concern in most high-end bait casters - the drive shaft ball bearing buried deep in the reel frame's starboard side. In a lesser reel most manufacturers use a cheapie plastic bushing. But in their Zillion, Daiwa does put a smooth-turning ball bearing in that hole, which makes a BIG difference in the smoothness of cranking, particularly under pressure. Daiwa went a step further than most, installing a corrosion-resistant bearing, but it STILL will rot, if not completely encapsulated in good marine grease. So that's what I always do.
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And here's the drive shaft back in position, sitting in its mini-tub of grease and screwed down tight, with its two hidden screws also well-lubed as a precaution against future rot-freezing. See that super-thin bearing, held in the cross-shaped white retainer? That's another point of potential trouble. It centers and supports the pinion gear and as such is constantly drenched in cast-off water from the spool. Daiwa used yet another CR bearing here, but it still needs regular lubing with a good quality oil to keep it free spinning. BTW, Here is proof that Daiwa was first to market with an "X-Ship" technology, not the "other" big Japanese reel company. Marketing is everything in sales, and NO ONE does it better than Shimano.

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Another point of possible trouble is the level wind worm gear's support. Let me explain - most reels have a bushing at either end of the level wind worm. Better reels use a bearing to support it on the drive gear end. This is good, for fresh water fishing. Not so good for us. It is likely that most bearings in such a location will not last a single season. In an effort to mitigate this problem, Daiwa utilizes yet another CR bearing. But corrosion-resistant is NOT corrosion-proof. So, to really stop this rot-out insanity, I bring in tiny pure ceramic bearings from China, and this positively addresses any concern at all. 100% effective.

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Part 4

Here's the reel's new 4.9:1 gear train completely installed and the reel's insides properly coated with my favorite lubricant/protectant - Yamaha Yamalube grease. Great stuff. What you cannot see is the new CarbonTex drag washers, installed DRY - for true h/d drag pressure. Daiwa, like Shimano, prefers to lightly grease their drags with special drag grease - for start-up and overall smoothness. This it certainly does.

However, the unintended consequence of using a drag grease is that overall drag performance is GREATLY decreased. Frequently this prevents the drag from being useful for our purposes. We don't hunt LM bass in some lake. We need lots of drag pressure to stop a nice one from hanging us in whatever bottom obstructions happen to be in the area. And so I ALWAYS set up my inshore reel's drags with dry washers. Seems to work for me, anyway.

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In addition to the CarbonTex washers, on assembly I further "adjusted" the drag's upper range by re-arranging and adding some additional washers to the drag stack. This requires a bit of a trial and error approach. It seems nearly every reel is a bit different, so multiple assembly/disassembly cycles are needed as differing drag pressure washer combinations and orientations are tried. This particular reel needed 6 tries to get it "just right." But that's what reel tuning is about.

From there its no more than a simple "buttoning-up" reassembly, using the parts illustrated in Part one.

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Sharp little bugger, ain't she?

Lep
 
Congrats on finding your holy grail! Good write-up, as always. There is no way I would have changed that screw o_O . Mag brake would not be functional afterwards,haha. Looks very sharp.
 
Beautiful reel Lep...my last Zillion family SV103 lies at the bottom of Raritan bay. With all the models Daiwa pumps out surely they ought to bring back the classic Zillion platform at some point. No T wing!
 
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