From: milos@inmet.camb.inmet.com (Bob Milosavljevic)
Subject: Build your own: an experience
Organization: Intermetrics Inc, Cambridge MA
Date: Sun, 27 Sep 1992 21:12:18 GMT

After getting some useful input from the Net, I recently finished
assembling my first self-built club. Last week, I played a couple of
rounds using the new club, and I thought I'd pass on some of my
experiences/observations, for what they're worth.

Sources of Components
---------------------
I requested and received catalogs from about a dozen different
mail-order component vendors. After spending a lot of timing poring
over the catalogs, I've concluded that, for the most part, Golfsmith
has the best prices and a very extensive selection from which to
choose. Based on two orders that I've placed with them, their
service seems to be prompt and efficient.

Choosing a club
---------------
I decided that my first home-made would be a driver and that I'd go
top-shelf in terms of components. I selected the 747-XL oversized,
kevlar-reinforced graphite head. Its specs: 9.5 degree loft, 54 degree
lie, 195 grams, 1 degree open face angle. A prime consideration was
my desire to build a matched set of woods - the 747-XL happens to be
available in 3- and 5-woods, too. As for the shaft, I went with the
True Temper Black Gold graphite shaft (S-300 flex, 91 grams, 3.0 degrees
torque, mid flex point). Again, a major consideration is the fact that
the Black Gold is also available for irons, leaving me the option of
using the same shaft for a complete set of clubs, including irons.
For the grip, I chose a Tempo half-cord oversized grip, hoping to
save myself some work by eliminating a couple of layers of build-up
tape. The cost: $39.50 for the head, $39.75 for the shaft, and $2.95
for the grip.

Putting it all together
-----------------------
Even though I'd been told that the assembly process was as easy as
1-2-3, I knew better. The trimming instructions for the Black Gold
specify no tip-trimming necessary for a #1 wood, so I lucked out there.
Prepping the tip seemed pretty easy - just rough up the last 4 inches
to allow a good epoxy bond. Since the hosel on the 747-XL is .335"
unitized and is pre-whipped with a neck ferrule, I expected to do very
little in terms of prepping the hosel. Boy, was I wrong! At first, I
was able to insert the shaft tip to a depth of only .75", well short
of the necessary 4" insertion depth. A couple of passes with a 21/64
drill bit did absolutely nothing to improve things; I spent almost
an hour very gradually trying to expand the size of the hosel opening
until I was finally able to insert the tip completely into the hosel.
Even after all that reeming, I still encountered a fair amount of
resistance when I made my test insertion, which really surprised me
because of the allegedly matched sizes of the hosel and tip (.335").
Oh, well, on to the moment of truth - the epoxy step. Not surprisingly,
I mixed too much epoxy for a single club assembly (about 4 drams), but
at least I managed to get the proportions correct. After filling the
hosel about 3" and buttering the tip, the final insertion went
incredibly easily. [Maybe I should have lubed the tip before trying
to make my test insertions??] The assembly seemed to dry just fine
overnight. Measuring the final club length for trimming the butt end
proved a little tricky because of a slight camber in the clubhead;
measurement varied by nearly .5" at either extreme, so I did my best
to split the difference. Trimming the butt to a final length of
43.25" (I wanted the final assembly to be .5" over standard length)
with a hacksaw was pretty simple, once I decided where to make the cut.
Installing the grip was also as easy as described: 3 layers of buildup
tape under the right (lower) hand, 1 layer of double-sided tape, a
generous application of grip solvent, and presto! - done.

The acid test: on the course
----------------------------
Being the impulsive and impatient type, I bypassed the driving range
and took the Beast right out to the course two days after assembly.
I haven't done the swingweight calculations yet, but I know this baby's
much lighter than my old club. During the round, I swung the club 10
times, hit 8 fairways, averaged about a 25-yard increase in distance,
and seemingly lost the slice that has plagued me for an eternity.
Needless to say, I'm ecstatic with the club and am ready to jump in
with both feet to complete the set of woods and then build a set
of irons. One of my playing partners in this round was a guy who had
a Yonex driver in his bag; after he hit a couple of balls with my
Beast, he commented that it felt a lot like his Yonex. I didn't
have the heart to tell him that it was only about a third the cost!

Conclusion
----------
I'd like to thank all the Netters who offered advice and encouragement
when I made my initial inquiries. I'm convinced - now, can anyone
recommend a Ping or 845 clone component iron head?


-- 
Bob Milosavljevic
Intermetrics Microsystems Software, Inc.       milos@inmet.com
733 Concord Ave.                               ...uunet!inmet!milos
Cambridge, MA 02138                            (617) 661-1840 x4606
Newsgroups: rec.sport.golf