Breaking down the US Reel Hibdon 810SX baitcast reel

[Fishwhittler]

I was recently sent one of these to clean and repair (the wave bar was malfunctioning), and while I had it apart I figured I'd take some pics and do a writeup.


(pic from Google - I'm reviewing a LH reel, but I couldn't find a non-CGI image of the lefty and the reel is currently in pieces on my workbench )

Apart from the fact that this is one of the ugliest reels on the planet, I was actually quite impressed with the fit and finish of this reel.  The frame and both side covers are metal, and the TiN finish is extremely tough.  There aren't any machining marks on the frame like you sometimes see on cheaper reels, though the handle and drag star do show some places where the machining was less than perfect.  The handle is an interesting handle, though it may not be universally liked.  I find the attachment mechanism gimmicky and a bit of a hassle, but it's serviceable.

There's a knob between the drag star and the handle.  You screw the drag star in place, then the knob, then the handle (the handle screws on like the handle on a Pflueger Patriarch), and then you tighten the knob against the handle.  There are teeth on the contact surfaces to help keep them from loosening.  It's secure, but it's not the most streamlined system.  Still, it's easier to use than the system used on the Pflueger Patriarch and the old President baitcasters.  I could take it or leave it.

Let's take a look inside.  We'll start with the handle-side plate:

That's a nylon bushing under the cast-control knob, but there are bearings on either side of the spool and the bushing only comes into play when the reel is under load.  This isn't a critical bearing location, and to be honest I'm surprised more manufacturers don't use bushings here on cheaper reels.

Brakes:

Typical magnetic brakes.  Turning the dial on the outside of the reel moves the magnets closer to or further from the spool, increasing or decreasing brake force.  I didn't do a whole lot of test casting with this reel before I broke it down, but I was impressed with how effortlessly it casts.  That's thanks mostly to the Wave Bar™.  The brakes are fine, nothing revolutionary.  This is a great reel for long-distance casting, and it could really shine for underhand casts.

Now for the stuff that makes this reel tick:

This is what you see when you open up the gearbox.  The clutch reminds me of that in my Pinnacle Producer X baitcaster (which is the same clutch as in the Wright & McGill Victory reels), but this one is different and executed considerably better.  This reel is well built and has a sturdy clutch.

Another angle with the gears removed:


Here's why I was asked to clean this reel:

You can see that the nylon worm-shaft gears don't mesh properly.  This is because the Wave Bar™ shaft that fits into the nylon gear is bent, and when the gear reaches a certain point in the rotation, this causes the gear to partially disengage as you see above.  The result is uneven line winding and a clicking noise inside the reel, and if not caught it will eventually result in damage to the nylon gears.  From what I've heard, uneven line-winding is one of the more common flaws in this reel.  I'd guess that the problem lies in the QC of the Wave Bar™.  It's cast aluminum, and US Reel needs to do a more consistent job with the casting process.

Last but not least, the drag stack:

Pretty basic.  The large composite washer is the same material used in many reels, and the lower washer is some type of fiber washer.  The drag is smooth enough once started, though it sometimes sticks on the startup.  Cal's grease should fix that, but a Carbontex drag wouldn't hurt anything.

Other notes:  The handle has four ball bearings, plus two spool bearings, plus two crankshaft bearings, plus the AR bearing.  The overall internal layout and design is very similar to that used in some Pinnacle reels, but with a lot more refinement.  This reel has its issues (such as the Wave Bar™ consistency), but a faulty clutch design shouldn't be what kills the 800/810SX.

The palm-side plate is a simple twist on, twist-off attachment mechanism.  Twist the side plate down (clockwise for the LH reel), and it comes off.  There's a spring-loaded pin inside the reel that helps keep the side plate in place, but the fit between the frame and brake case is snug enough that it's probably never going to loosen on its own even without the pin.

As I see it, the strongest points of this reel are the sturdy build and the excellent casting.  The 800SX is truly an excellent caster.

Now for the cons:  The clutch bar is plastic, and it just seems a little flimsy.  I'm nitpicking here, but they might have used a slightly more rigid plastic.  And, the Wave Bar™ needs refinement.  The concept is great and really works, but I've heard too many stories of uneven line winding on these reels to think the bent level-wind shaft is an isolated incident.

I've contacted US Reel about ordering a replacement Wave Bar™, and now I'm waiting to hear back from them if the part is in stock.  The part is $8 plus $5 shipping, and if you get a good one, it should take care of the line winding unevenly.  I'll point out that it only exhibits that problem under load, so you might not be able to tell if your reel has that problem until you actually take it out and catch fish, or spool it up and tighten the drag enough to put significant pressure on the Wave Bar™.

Bear in mind that this is strictly based on what I've seen while taking apart this reel.  The design is fine and the reel has a "polished" look to it.  It looks and feels sturdy, but only extensive use will tell how the reel holds up.

The US Reel Hibdon 800SX is very, very good at casting, but the Wave Bar™ quality control leaves something to be desired.  Other than that it seems like a nice reel—though it looks like a chrome potato.  Unless US Reel addresses the Wave Bar™ problems, the US Reel 800/810SX is not a reel that I'll consider purchasing unless I can find one for really cheap.

Tight lines!

Ben

[Mike Cork]

Good write up, thank you. I tackled one of these the other day I found some wear areas that were significant, could have been user issues though.

[Fishwhittler]

Good write up, thank you. I tackled one of these the other day I found some where areas that were significant, could have been user issues though.

That's true.  Some companies may use materials that wear more quickly than others, and I've edited my post above accordingly.

If you don't mind my asking, where were the trouble spots inside the reel you examined?

[Mike Cork]

The reel was brought to me with issues of re engaging. After a cast he had to work the reel to get it to re engage the spool. After cleaning it was better but when I removed the clutch you could see where it was digging into the housing some. The springs were fine. Also the thumb bar it's self was digging into the housing as well. Just put a damper on how smooth I'm sure it was when it was new. I have no idea the abuse this reel took nor how long it had been in need of cleaning so I can say that this is a common problem, only that I seen it on this reel.

[CraigP83]

Sweet write up, very informative!

[LgMouthGambler]

I wasnt too crazy about the designs of those reels, and this furthers my questionable thoughts about them.

[Fishwhittler]

The reel was brought to me with issues of re engaging. After a cast he had to work the reel to get it to re engage the spool. After cleaning it was better but when I removed the clutch you could see where it was digging into the housing some. The springs were fine. Also the thumb bar it's self was digging into the housing as well. Just put a damper on how smooth I'm sure it was when it was new. I have no idea the abuse this reel took nor how long it had been in need of cleaning so I can say that this is a common problem, only that I seen it on this reel.

Thanks for the info!  The reel I'm working on has been used though not extensively, and while there's some wear in the paint where the thumb bar rubs against the frame, the metal itself is fine.  Other than the faulty level-wind, the reel is in great shape. 

I can't say from experience if this issue is present in other 800SX reels, but on the other hand, the level-wind works only when there's little tension on the line.  If the reel is under pressure, the bad part makes the line lay unevenly.  The concept does work, and with a straight level-wind shaft it would be fine.  Unfortunately, the reports of uneven line winding from other owners of US Reels make me think that it's not an isolated incident.

Anyway, I hope this thread is interesting if nothing else.

Tight lines!

Ben