Trev And The Search For The Perfect Wire

The first hurdle I faced while developing our stickbaits was perfecting the wire setup. Big lures mean big fish, and whether you’re casting from a boat or shore, a trusted length for landing the big one is 240mm. After days of scouring the internet for ready-made solutions with little success, I decided to develop my own wire-bending system. Custom fishing gear requires custom solutions, and that’s exactly what I set out to create.

The Wire!

The first step was choosing the right wire thickness—stainless steel was, of course, a must. From the outset, 1.5mm wire stood out as the prime candidate. It offered the perfect balance—rigid enough to secure a catch even if the lure broke, yet flexible enough to be bent with precision. For targeting species like kingfish, strength and reliability are non-negotiable, especially when you’re deep in the action on the water.

Jig on jigs on jigs:

Next came the challenge of straightening the coiled wire into usable lengths. To solve this, I created a jig utilizing an old spool and several bearings to guide the wire through, which worked perfectly for straightening. With straight wire ready, I moved on to cutting and bending—essential steps for any custom fishing project.

Bending the eyelets presented a minor challenge. After some trial and error, I settled on using a rotating 3-point bender, which provided consistent and precise eyelet bends.

But the real test came with the mid-body U-bend. This required a more complex setup with three pins and a twisting handle to ensure accurate bends. Extra care was needed to avoid over- or under-bending the wire so that it fit snugly into the stickbait during assembly, ensuring it performs well when retrieved in water or when casting for those hard-fighting kingfish.

An exciting addition came later—the inclusion of an eyeball on the wire. This unique feature not only enhances the lure’s appearance but also adds a bit of realism that’s sure to tempt predatory fish. I believe this feature is a real standout for our custom fishing gear and plan to expand on it in a future article.

To Crimp or Not to Crimp?

During my research, I noticed that many pre-made wires relied on twisting the wire itself instead of using a crimp. While effective, I found this method to be unpredictable and difficult to replicate consistently by hand, making it harder to fit the wire into the lures. To address this, I opted for aluminum crimps on both ends, ensuring a secure and reliable finish. Whether you’re casting for kingfish or trolling from a boat, this setup ensures the wire won’t fail when it matters most.

With a reliable wire-bending system now in place, I’ve taken the first big step toward creating high-quality, durable stickbaits. Whether you’re using a top-tier fishing rod or just enjoying a day on the water, these lures are designed to deliver. Stay tuned for more insights and innovations as the journey continues!