Penn Jigmaster 500 Drag washer upgrade old timer's tip 

I wouldn't recommend tearing into them, but I get your point! Thanks for the feedback. Please stay tuned as there are more to come - Dennis

Thanks for the tip! The shooting spring is everyone's nightmare and fear! Best wishes and thanks for the shout out to the small tackle shops. They provide a valuable service that the big chains don't care to do - Dennis

The Penn Reels have certainly stood the test of time. I'm happy to see they are still out there fishing - Dennis

Thank you. I also found that the inside frame screw of the Jigmaster is the same threading as the handle set screw. Like you mention, you may need to file the head to fit in the recess - Dennis

Thank you for the feedback. Best wishes for great fishing with your new old reels - Dennis

I just picked up Penn special Senator 3/0. Do you have a video on this ?

484 model this is on the JC Higgins.

All of the Jigmasters have the same internal gearing and configuration. This video will work with your 80's Jigmaster. Good luck with the tune up. Keep that reel fishing - it is a good one - Dennis

Thanks - I'm going to try and find that washer somewhere to add it ! (I have found a little weakening of the drag in recent years). I love that reel - I've cleaned it religiously after every single fishing session ever since I bought it as a broke student, it's still as good as new. I'm taking it with me to the grave .

Dennis Kuntz already subbed. I noticed you didn't mention upgrading the gear sleeve if you put in the better drags. Stainless steel gear sleeves are available online.

Booboi010 i did the stainless upgraded gear sleeve, stainless eccentric jack, shorter spacing sleeve and the carbontex drag washers. Also all bearings were replaced. Has plenty of drag and can free spool like crazy. Gonna use it for bottom fishing. Is it ok for school sized tuna or would a 113 6/0 be better? Ive been renting rods at helgrens the last couple years and they all seem to be in bad shape recently.

Most of those clickers are peened on and hard to replace. If you have rust, flood the area with a penetrating oil or rust buster. It will free up. The click shaft is metal, but the case is plastic, so working the click in and out will eventually wear the rust off and restore the function - Dennis

There were various aftermarket Penn handles, but it is what's inside that counts. Thanks for watching - Dennis

@@2ndChanceTackle I don't think it's aftermarket but I could be wrong. I've seen other Bakelite knobs but not like this one. Looks like a marble to me. Waiting on drag washers, they were hard as a rock stuck to the metal washers, but it will be fishing in no time.

OK - If it is the maple/caramel color, then yes, those are one of the earlier bakelite handles. I was thinking a bright orange! - thanks for the update - Dennis

@@2ndChanceTackle that is the perfect description. It's most certainly an older JigMaster, it's been quite a project but it's looking as good as possible!

I appreciate the vote of confidence! Spread the word to subscribe. Thanks for watching - Dennis

Thank you

Thank you - Dennis

You bet - Thanks for the note and for watching - Dennis

You are welcome!

Please! Give it a new lease on life. With a proper overhaul, you can make this last a long time!. If you have sand in the reel, take the side plate off and put in in a pail of water to let it flush out. Oil is used on the gear sleeve (handle shaft). The rest should get grease. It is OK to use oil on the metal parts, but it evaporates much quicker than grease and loses its slip. - Dennis

@@2ndChanceTackle thank you very much Dennis. I will. I just cleaned it and is way better,the parts are all in good shape. No rust. Just a bit dry the drag parts.But i will do the water wash to remove all the sand and put new grease and oil. The reel itself is very good. Im surprised. Thanks again!

Sure thing Eric - Send it to me and I will make sure it is done - Dennis

Thank You Dennis .

My pleasure! Thanks for watching

Thanks for watching - Dennis

You need the small diameter on the top to fit in the recess of the inner case. The larger Jigmaster washer can bind in that position. That's why you use the on from the Long Beach series - Thanks for asking Dennis

Thanks

You did well with your garage sale find!

If you have the Long Beach 66,67 or 68 or the Senators 4/0 and 6/0 you should be fine for 70 pound class. You can use the Jigmaster, but that doesn't have the line capacity. The 209 has a line guide, so not recommended and it also has lower capacity and you will lose one to line run out if it takes off. - Dennis

Yes - the side plates are basically the same, so you have room to add the additional washer - Dennis

The Jigmaster drags are part 6-309 1180917 The Long Beach drags are part 6-60 1180906 you can order these through Mysticparts.com - Dennis

@@2ndChanceTackle Thank you Dennis!

My guess is that the drag washers have dried out and are frozen to the metal washers, so you have all or nothing at all in adjustment. You will need to replace the washers if that is the case. You can get replacement washers through Mysticparts.com Thanks for asking Dennis

@@2ndChanceTackle Thanks! I hit them up as a matter of fact too to see what they had to say. They also said that no washer goes between the side plate and wheel for the 500, and there are in fact three. I am verifying I understood them correctly in that regard. Thanks again.

@@2ndChanceTackle Got it apart and all in pretty good shape. Greased up where suggested and used Zep 45 where Mystic calls for Corrosion X (don't have that). I think maybe the spacing sleeve isn't exactly right (no part number on it), and that's why wheel is limited. So getting a stock one to see.

Sure - you can order the washers through Mysticparts.com. Here is the page link. The washers are part key number 6 www.mysticparts.com/PennParts/Penn60.aspx Thanks for asking Dennis

Has anyone tested a before and after to see if it increased the drag by adding the 60? Thank you!

There is an aftermarket set of carbonated washers available through mystic parts.com that adds 2 more drags and 2 more stainless washers. It's not cheap, but it will increase drag by approximately 40%. Other than that, the extra washer that was discussed in the video is about it. On the Warfare and Small, I don't know - Dennis

I may have left the first fabric washer in the main gear as I was showing the top washer here. You are correct. the sequence inside the reel is fabric first then alternating metal and fabric ending with the metal on top. - Dennis

@@2ndChanceTackle Thank you for your kind reply.

No need to change out the gear sleeve Dustin. It is just a spacer that applies pressure to the drag stack. It does not move - Dennis

Not that I know of. There are some power handles that are aftermarket. Mysticparts.com sells the offset handle blanks that you can add the power knob of your choice to. You can see that item in the link below www.mysticparts.com/Custom/ProChallenger/24-500-1-PC.aspx. Dennis

Sure do! I repair reels and when they come in I always recommend that they change the line. My guess is some folks think braid lasts forever....It doesn't. They use the reel a few times a year and think, gee, I've only fished it a few times, must be good. They don't realize the the saltwater and UV rays beak down the line, regardless of how many trips you have been on. This for the note - Dennis

Those bolts and wing nuts, and hopefully the clamp, are used to tie down the reel to the rod and hold it firm so that it does not come loose while fishing - Dennis

Not possible using the standard configuration. MysticParts.com sells an aftermarket kit by Brian Young called the ultimate drag upgrade, that adds two more Carbontex washers and reduced the width of the metals by using stainless ones. As a result they have more washers in the same stack size. They recommend changing over the pinion gear to a stainless upgrade as well. You can watch how this is done to a Penn Squidder. You can do the same to the Jigmaster. It is not cheap, but it does increase the max drag of the reel. here is the video link ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-RsRA1tM47jw.html. Dennis

@@2ndChanceTackle The link you posted meant to direct me to the Penn Squidder, actually takes me to a Daiwa Procaster 10G. I searched your videos though and found the one you are referring to. Thanks.

I don't think you have the room to add the additional washer to the others. They also don't take the same load as the JigMaster, so I would leave them alone - Dennis

If it is stiff, try backing off the side plate bearing by turning it counterclockwise. There needs to be some side play in the spool. When you service the reel and add grease to the bearing, it often reduces the side play, so try backing that off and see if it makes a difference - Dennis

It has a place, but it depends on how much fishing you are doing. The stainless sleeves and gear set are for heavy use reels. If you are going out 10 times a year, there is no need to upgrade. If you have a commercial boat or are fishing daily, it could be worth it. Many charter boat captains stick with the basic reel and do not upgrade. The cost is almost equal to a new one, so when they fail, they replace. - Dennis

Unfortunately, there is no easy answer there. Is it a post screw or in the frame? If it is the post screw, remove the one holding it from the other side. That should allow you to separate the case. Once that is apart, try turning the post and not the screw to unwind it. If that doesn't work, the only option you would have is to snap off the post and hope there is enough of the stud remaining to would the tag end out. If it is the reel seat, try removing the other side plate as noted above and the try unscrewing by turning the reel seat rather than the screw - Hope that helps - Dennis

@@2ndChanceTackle Thanks for your advice. I thought about similar options. A tool and die maker friend of mine is taking a look at it. I will let you know what he comes with.

My tool and die maker friend was able to get the broken screw out of the 1978 without any damage to the plate. Have any idea what screw from a Penn reel may fit a 1978?

You can get the wrench at Mysticparts.com. Enter wrench in the search terms and it should come up with the product. I believe it is by Alan Tani - Dennis

Saw your other note - Thanks - Dennis

Sure. Is it the red or black color? Is it the gear (handle) side or the bearing side? Please contact me at 2ndchancetackle@gmail.com and I can send you a replacement - Dennis

David - Please contact me through my email - 2ndchancetackle@gmail.com. Thanks you - Dennis

Hi Frank. Both methods are acceptable. If you are using this for casting and are able to take the reel apart and lubricate if every few trips. then use the oil for better results. The Jigmasters I am showing you are normally used daily for drop fishing on charter boats. They run the reels until they break. With that kind of usage, I prefer the blue grease, which holds up longer and does not evaporate and dry as quickly as the oils. The blue grease also does not run off to other parts of the reel when stored, as oil does since it will find the lowest point of gravity. - Dennis

Thanks for your quick reply. I will try that 6-60 washer in one of my jigmasters also. Have a happy and healthy new year!

Best wishes for a Happy New year filled with great fishing - Dennis

John - your anti-reverse dog is not engaging. It is a fairly simple fix. I am not sure if your part is damaged or not. I will do a video for you to show how it is done. If you do not have the part or parts needed, I can mail it to you. Give me a few days to do the video - Dennis

@@2ndChanceTackle thank you so much such Dennis

Hi John, I thought it was a bit insulting to say to toss your late father's reel! They want you to buy new reel(s) from them! I have some of my father's old reels which I appreciate! I made an anti reverse (dog) lever from a flat yale type key! The hole in key is a perfect fit on the point in plate & thickness too! I used a hacksaw & file. Also, I made (cut) a flat metal spring strip from an old wind up clock, that goes into position, that pushes the anti reverse lever into position in a Penn 49 reel! Bend that flat spring into a Slight L shape to fit around those points on the plate there! Over bend, will snap it! Have to be careful when fitting a new original one as to over bend will weaken it's tension! Regards, , I am in Port Elizabeth

I love it when folks show their creativity- The era of the fix-it man id dying - Dennis

@@michaeleverton4882 thanks for the the advice, I have received 20 Penn jig masters from people all over the East London in Gonubie, I had a look at the Yale key, you are right Michael, it fits well

I don't believe any scientific study has been done on this old timer's trick. In theory it should, because there is more area involved. The purpose of the extra washer is to take out the slack and give more crank down pressure, but the end result may and could be additional drag. Thanks for asking - Dennis

Yes; I believe extra drag power effect!

You can get these at Mysticparts.com. They are an authorized Penn Parts distributor - Dennis

I don't have any Newell reels currently in the shop. One of the best tutorials I can recommend is by Alan Tani. Go to Alantani.com and search for TUTORIAL: 220-5 . This is a step by step how to in pictures, not video. I have referenced it several times as I do not get many of these rare reels any longer. Most have gone to collectors and are no longer fishing.

That gets tight

So after much fiddling I have figured out that when I offset the spool more towards the non handle side the issue doesnt happen. But when the spool is centered or towards the handle side it becomes jerky with tension on the line. Any idea for a remedy? Worn bearings? Or could it be the custom machining of the spool itself? I was just finishing this build and very ready to test it out this Sunday offshore here in southern california.

Here are a couple of thoughts without seeing the reel: Did you also match the SS gear sleeve to an SS main gear, or are you using the original? The play in gears between the two different ones could cause a choppy retrieve. The second thought is the shim washer on the gear sleeve and under the main gear. Did you replace this? If not, is is clean and free of debris? Last is to make sure the new drag washers are in correctly and that the metal earned washer is seated properly. The earned or keyed washer needs to be the second metal in and fit in the slots. If it is first or third, or mis-seated, that could also cause the problem. If these ideas don't work, and you have the old Jigmaster, swap the side plates to test and see if the problem exists using the original frame and spool. I hope this helps - Dennis

The washer that is right under the main gear was replaced with a carbontex washer. Identical Dimensions to the original Delrin washer. The main gear is the original so I'll look into that. And lastly ive done drags on these reels many times so I'm sure its in the correct order but I will double check just in case something shifted during assembly. I'll inspect these things and see waht I find. Thank you so much for helping !

OK. If possible, I would still put the new side plate assembly on the old frame and spool to make sure it is in that part and not the frame of non-gear side bearing. If you put the new side on the old frame and spool and you get the same problem, then you can reaffirm that it is in the gear system.. IF you do not get the chatter, then it is in the frame/bearing/spool. Just a process of elimination - Dennis

Got it. Thank you so much. Im going to put it back to it 500 config and see what happens.

The 200 is a different reel with a lower gear ratio that is based on the Penn Long Beach line. You can go ahead and try adding another washer, but I am not sure if it is needed or will make much difference in performance. If you do attempt this, let me know the results - Thank you - Dennis

I don't think there is as much room in the other cases to add a washer. Also, the reels like the Squidder have lower gear ratios and a lot of lifting power as a result. They may not need the extra washer under most circumstances

@@2ndChanceTackle Thank you Dennis

Yes. I should see some come in soon as the tuna season will be ending shortly. I usually get these to rebuild over the winter

Cal's universal drag grease. It helps keep the drag washer flexible - Dennis

2nd Chance Tackle thank you, I just bought an old one on eBay, haven’t got it yet. Would like to restore it to use for catfish.

Yes- The Jigmaster bridge is designed to hold the dawg on a stud with the spring connected. It can remain in place while servicing the reels gears and drag washers. This is different than most earlier Penn reels that attach the dawg with the side plate screw. The models using the side plate screw attach method include the Long Beach, Beachmaster, Surfmaster and Peer fishing reels.

Great! I just bought one to add to my vintage reel collection. That will make re-assembly a little easier after a thorough cleaning . Thanks Dennis.

Received my Jigmaster today. Great looking reel in excellent condition. Just can't figure out how to get the side plate off of the drive side using that thumb screw. Any ideas?

Yes sir! Turn the thumb screw counterclockwise a few turns then Pull The screw towards you like you are pulling it out of the case. This screw is spring loaded and you need to pull it out in order to free it from the hole. Once you have it out of the ole, but not out of the side plate, grab the handle and turn the handle counterclockwise. This should allow you to move the whole side plate and detach it from the reel. I will do a video for you and post this evening - Dennis

Here you go Brad. I did a video to show how it is done ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-rAgeKuxiaZc.html Dennis

If you have side to side slop or excessive play, the problem is going to be in the gear sleeve or the bridge post. The best way to check this is to take the bridge assembly off of the side plate then grab the gear sleeve and pull/push back and forth. It you are seeing the gap at the bottom of the gear sleeve where it meets the bridge increase and decrease as you are doing that, then one or the other piece is worn. Sometimes it can also be that the pin that holds the gear sleeve onto the bridge post is worn, broken or missing. In any case, the extra washer will not fix that problem. Either the gear sleeve, bridge plate or both will need to be replaced in order to fix the problem. Thanks for asking - Dennis

I am not sure if there is enough room inside the Senators. Their drag systems vary. I think you could give it a try to see. The worst that could happen is that the reel would be too tight, and you would have to remove the extra washer - Dennis

The drag washers are available through Pennparts.com. You may also find them on EBAY. The Penn part number is 6-60 and there is a subpart number on the sit which is 1180906. You will find them by searching for conventional reel parts and look under the Penn Long Beach 60 model. You can also pick up new JigMaster drags washers on the site as well. - Dennis

I believe you will have room inside the reel to add an additional washer, but the 209 does not use the Jigmaster drags. The 210 has the bigger drags. - Dennis

@@2ndChanceTackle Thank you so much, would u suggest I do this to a 209 series reel? Do u have an idea what size smaller top washer I could possibly use?

I think there is plenty of drag in the 209, but if you want to add the additional washer, use the one from the Beachmaster 155 series as the top washer. Thank you for asking - Dennis

@@2ndChanceTackle Thank you once again sir

marine*

You can use it, but I still prefer reel specific grease. Take the time to order a small container of it on Amazon - It will run less than $10 for an oil and grease combo pack - Dennis

You need to identify the problem first. If the screw is no longer in the spring collar and pulls out completely, then that is not correctable. If the screw grabs the side plate and holds, than that is the best outcome. You can use it as is. If the screw is stripped and does not hold, you can get a replacement screw. I can send you one if you need it. If you want the spring loaded as new function, then you need to replace the side plate. - Dennis

it pulls out but it still holds. I can use it the way it is . I have a squidder that has the same problem . they both hold nice and tight still. so that's good. thanks very much! ...gary