From kitchen prototypes to the first finished rods

After the prototypes were completed, my excitement quickly shifted to the next challenge: finding a rod maker who could help turn these experiments into real rods.

Thanks to the internet, the entire world suddenly sat on my desktop.

Unfortunately, none of the rod makers in the United States were interested in building a small run of prototypes. Some quoted prices that were simply out of reach. Others required long lead times—six months at minimum—along with large upfront deposits. At the same time, Japanese and Taiwanese rod builders weren’t interested in prototype work either. Many preferred to sell existing designs or tell me what they thought was best for me.

I wasn’t looking to be sold a rod.

I was looking for someone willing to build one with me.

I searched through countless listings on platforms like Alibaba. Most factories wanted to push what they already had in stock. Others were unwilling to deviate from their standard designs.

Then I found a small rod maker in China with a very different response.

“Tell us what you want,” they said. “We’ll do our best.”

That was all I needed to hear.

I explained that I wanted to go through at least three rounds of prototypes, each built to my specifications. Their response was straightforward:

“No problem—we’ll send you the PI options.” (PI stands for Purchase Invoice.)

The standard turnaround time for a prototype was about four weeks. If I wanted it completed in less than two weeks, the cost would double. I chose speed—I couldn’t wait to see the first result. Even at double the cost, a two-week turnaround, combined with international shipping via FedEx, was still faster and more practical than any other option I had explored.

The first batch arrived quickly: three prototype rods, each built with different materials. This allowed me to closely inspect carbon quality, construction consistency, and overall craftsmanship.

After extensive handling and testing at the casting pond, I settled on Toray 46T high-density carbon, roughly equivalent to IM12. It was noticeably lighter and more responsive than lower-modulus options. The trade-off was higher cost and slightly reduced flex—but it aligned with my design goals.

The second round of prototypes focused on improving flexibility and refining craftsmanship. I worked directly with the factory’s rod engineer, and to speed up the process we conducted strength tests and live rod-bend curve evaluations over Skype. This approach saved both time and shipping costs.

By early February 2015, ten final rods were delivered with a simple label: Fatmonk 360 (360 cm). Ten rods were enough for me—to fish extensively and to gift to a few close fishing friends.

I was thrilled.