Tuff Tackle. Technical reviews
Tuff Tackle Pty Ltd is an Australian owned private company that works with international contractors designing, building and testing spinning reels and rods.
The Diablo range of reels is designed by the owner and founder of Tuff Tackle Pty Ltd, using many Australian made parts.
Tuff Tackle has developed unique assembly techniques, to create a 0% mechanical fault rate in manufacture.
All testing of proto-types and production models is carried out with the assistance of professional charter operations both in Australia and overseas, to make sure any reels are virtually bullet proof in the final design before retail release.
As well as mechanical cycle testing, Tuff Tackle reels are subjected to the real world of actual full time fishing, as well as a very high level of assembly techniques, that guarantee no chance of mechanical failure while hooked up on the fish of a life time.
We don't use made up terms to baffle the consumer to describe our technical specifications, we use the proper engineered descriptions, so those that are familiar with engineering know they are not buying a toy dressed in armour. Our body armour houses precise and well engineered machines designed to go the distance in any environment including the most brutal (Charter operation)
Diablo reels range from assembled in Australia to made in Australia from imported and locally made components.
2010 will see the release of the first 100% Ozzie made Diablo reel, and will be something very special (Stay tuned)

Material notes:
Facts relating to use of suitable materials for fishing reel gears
The gears used in spinning reels need to be of a specific material and manufacture process, according to their expected load rating.
Hypoid gears (as used in all spinning reels) is a gear operation that requires bearing properties to reach the highest possible strength and life span. Because of the nature of 'Slicing' action performed by the main gear slicing the pinion gear, like a plain bearing.
Therefore, Reels designated for light duties and economical costs, use Aluminium or Duralium gears, reels for heavy work, such as deep sea jigging or game fishing require true bearing materials such as Bronze alloys, or Steel alloys.
A suitable bearing material is determined by it's coeficient of friction (the lower the number the better) Secondly the hardness and sheer strength of the material chosen, to withstand extreme loads.
Aluminum cast or forging alloys:
High coefficient of friction 1.35 (wears out quickly, economical to produce)
Aluminium cast of forged : Suitable for light duty low to mid range spinning reels
Low cost to produce
Duralium Also known as Duralumin (Aluminium, copper alloy) :
High coefficient of friction 1.20 (wears out quickly, economical to produce)
Suitable for medium duty mid range spinning reels (wears out moderately, economical to produce)
Harder than Aluminum
Lighter than plain machining brass
Low cost to produce
Brass machining:
Medium to low coefficient of friction 0.3(similar properties to duralium, in hardness, lasts longer than duralium under loads)
Similar hardness to Duralium
Must be machined (higher accuracy and thermal stability compared to Duralium)
Heavier than Duralium, more precise manufacture tolerances.
Medium cost to produce
Bronze:
Low coefficient of friction 0.16(harder than machining brass, or the magical 'Hardened brass' or duralium or aluminium)
Must be machined (higher accuracy than Duralium or aluminium)
Hard wearing, higher strength compared to duralium or brass
High cost to produce
Stainless steel:
Low coefficient of friction 0.05
Must be machined (high tolerances can be achieved for perfect bearing surfaces)
Higher sheer strength and hardness than bronze, Brass or Duralium
Excessively high cost to produce


Materials choice for spinning reels gears. Pro's & Con's
Duralumin:
Pro's:
Quiet running (absorbs metallic sounds), Light weight.
Con's:
Limited strength, Fatigues over time, Becomes more brittle with age, decintegrates quickly without lubrication, once worn requires replacement to maintain correct gear mesh.
Brass/Bronze:
Pro's:
Strong, long life span, durable, requires minimal lubrication.
Con's:
Noisiest material for gears, requires simple servicing to maintain correct gear mesh every 3000 hours
Stainless steel:
Pro's:
Incredibly strong, hard wearing, quiet running
Con's:
Requires simple servicing to maintain correct gear mesh every 3000 hours
DIABLO 9000

DIABLO 9000 series 3
TuffTackle DIABLO 9000 series 3 review
80lb line class reel 2009/10 model This review is of the mechanical improvements of the Series 3 DIABLO 9000 As per the previous (2007/2008 models series 1 & 2) DIABLO 9000. We have made many significant changes in the mechanical design of the Series 3, resulting in a smoother and more powerful reel going from 50lb line class to 80lb line class for the series 3 The first obvious change is the drag clicker assembly. The Series 3 has a permanent rivet,
Old spool / New spool clicker design

Series 2 (old reel) is on the right, Series 3 (New DIABLO 9000) left

The second obvious change for series 3 is the bearings.
We assemble all DIABLO reels in Australia for 100% quality assurances during assembly.

The bearings are all etched with the ‘S’ symbol (Stainless)
Tolerance is Normal Radial ball bearings ZZ (double shielded, passed salt fog test)
The Third obvious change is the spool and bearing assembly
New series 3 main shaft

Older series 1 & 2 shaft design
The new main shaft design has been changed for higher strength and is more easily serviced.
This provides a more easily serviceable spool and bearings as well as a more durable brass clicker gear, combined with a completely round bearing surface for a very stable (non wobbling) spool whether the drag is tight or loose.As well as a stronger hardened Stainless steel shaft, due to a shorter flat section compared to previous 9000 models

Below you can see the position of the spool bearings
Close up of spool bearings


Shaft assembly without spool fitted

Not so obvious is the new gears and the gear arrangement, for better winching efficiency and machined rather than cast as used in the previous models.Combined with the anti reverse ratchet that is a backup if for any reason the large one way bearing slips (eg grease gets into it) The new main gear was moved closer to the pinion gear, by reducing the diameter of the main drive shaft as you can see in the picture below.
The old main gear and oscillation gear was a cast one piece arrangement.
The new cut main gear has a separate oscillation gear, that floats perfectly in alignment with the other oscillation gear, enhancing efficiency yet again.The practical result is that where the old model tended to lock up under winching load, the new and more efficient gear arrangement allows retrieval of say deep water species with a lot less effort, which is ideal for charter use, and extends the gears working life.

New main Gear (Digitally cut)

New Series 3 Machined main gear (pictured above).

Every component is checked before assembly

Back up anti reverse ratchet

Anti reverse ratchet visible on top of the main gear, secured by 6 screws (Above)
The pinion gears on the S3 is Manganese Bronze (harder than steel) almost impossible to scratch with a file, and an excellent plain bearing material.
The main gear of the S3 is machined from solid DR (corrosion resistant) brass containing Silicone and other impurities to stand up to extreme loads and extended life.
Basically a bronze, suited to the application of ‘slicing’ This as well as the straight cut oscillation gears are cut on a digital NC hobbing machine. A very precise way to make gears, compared to casting or forging.
In fact the gear mesh is so precise, we had an issue keeping it lubricated without all the grease squeezing out of the mesh of the gears on the first turn of the handle.
I will explain how we resolved the lubrication problem later.
Another obvious change was the cam, the old one was brass.
The new one is the same as the new body material Al-Si-Cu-Mg (we added magnesium (Mg) (Same material used to make engine pistons)
This alloy is just as strong as the brass cam, but lighter, and an excellent low speed bearing material, which extends the life of the pinion gear fit, and removes the need to use a bearing at the bottom end of the pinion gear, because bearings in the application are required to be thin and therefore lack a decent life cycle to meet 10 years of use.
The position in relation to the main gear allows self lubrication from lubricant thrown off the main gear (perfect and simple) just the way it was intended.

Lighter cam design
‘S‘ cam oscillation. New version is lighter, and just as strong
Another improvement is the bearings on the cam, the one taking the highest load is a solid brass bush.
The one taking the least load is a Stainless steel roller bearing.
These bearings and cam are what takes the drag load transmitted down the shaft So no matter what happens to the reel, these 2 bearings which allow the cam to slide up and down with the main shaft, will never need servicing, even if debris got into the reel somehow, or from wear particles mixed in with the lubrication.
All that means is a smooth oscillation for the life of the reel.
With a reduction in weight of 45 grams over the older models as a bonus, now coming in at 750 grams. On the subject of oscillation, spinning reels are generally made in 2 types.Cam drive (commonly refered to as ‘S‘ Curve) because the cam looks like the letter SWorm drive which is where the main shaft is driven up and down by a screw drive.
Cam drive is stronger and involves very few moving parts, but also requires more energy than the worm drive to operate.
The worm drive has more moving parts, is extremely efficient and smoother in comparison, but is weaker by design, and therefore a weak link in the chain.
So with worm drive oscillation reels, you are more likely to experience a spool that feels loose (up and down movement) a lot sooner than a cam drive oscillation reel.
This is why we only use worm drive on surf reels, to lay the line perfectly for better casting distances, with reels that are subject to less load than a reel used on a shorter boat rod.
A worm drive reel will cast better, feel smoother, but will wear faster.The cam drive will just keep going and going, regardless of wear.

Worm drive oscillation (surf reel pictured)

Worm Drive oscillation set up, the extra shaft at the bottom, is more efficient but weaker in design strength, and wears quicker than Cam drive.
Cam drive oscillation design
Cam drive oscillation for high strength and reliability (Early series 4 proto-type pictured above showing oscillation gears and cam underneath the main gear) Our biggest customer base for the DIABLO 9000 series 3 reel is proffessional charter operation which is what it was designed for originally.
Bullet proof, simple, reliable, easy and less service requirements, with ranges from 3 – 37kg fishing, bottom bashing, winching from great depths, smooth reliable drag up to 20kg. Bottom line affordable, and no compromise or weak links in the chain, for most fishing types, within the majority of the charter industry.
The series 4 (DIABLO SNIPER 10000) is the reel for demands beyond the above, with a 130lb line class rating, compared to the 9000 80lb line class rating.
The new drag has also improved over the older models were very course in adjustment with the low ranges from 3 – 8kg being very hard to adjust finely.The new drag knob and sandwich woven carbon skin washers with woven class core laid with epoxy resin giving a more consistent adjustment for about ½ turn per 5 kg at the lower end and 1 turn per 5 kg at the higher end from 10 – 20kg.
with no possibility of delaminating under extreme heat.With the addition of PTFE, being pressed into the sandwich sheets using a vacuum, before cutting of the discs with a specially made punch.

Diablo 9000 Series 3 Drag washers and Spool

DIABLO 9000 Series 3 Drag washers and top bearing pressed into spool
The washers are lubricated using INOX MX8. which thanks to the guys at INOX and their help we have the lubrication spot on in the right applications for each part of the reel, to provide an extended life of all the moving parts as well as minimizing any wear under heavy and extreme salt water conditions.
We didn’t just take INOX’s word for it, we constantly test lubricants on DEMO reels in real world applications with charter customers.
This is where we solved the lubrication issue of the main gears, as normal reel grease squeezed out completely, so with the addition of an adhesive in the grease the main gear retains and re-applies grease on every spin, so the reels generally don’t need grease injected into the lube port for aprox 3 years.

To make life even easier the reels are sold with 1 x free service within the 10 year warranty period, where we pull down the reel, and re-lube give it a good clean and service from top to bottom, and re-shim the gears to take up any free play from normal wear on the gears meshing together.