Ultralight Fly Fishing Box

DIY: Ultralight Fly Fishing Box

I’ve been on a bit of a Tenkara kick lately, every since receiving my new Iwana rod and other pieces of Tenkara fishing gear from Daniel at TenkaraUSA just a few weeks ago.

Unfortunately for me there aren’t any specialized fly fishing stores near where I live in North Carolina, unless someone knows of any? About the only place I can physically drive to and look at gear is my local BassPro store which has a dedicated fly fishing section, but it’s old school, snobby, predictable, and the gear is kinda bulky.

Of course I could order all manner of nifty pieces of gear online and I probably will, but that doesn’t satisfy my hunger for instant gratification. So, being the geeky gear junkie that I am, I decided to start making some of my own lightweight Tenkara gear – starting with a fly fishing box.

DIY Fly Fishing Box

I knew that I wanted to make a small fly box to hold a handful of dry flies and maybe my Tenkara line and a spool of tippet, but that’s about all. I went to my local Walmart and bought a small Plano fishing tackle for $1.50. It was definitely small enough and at that price I didn’t much care if I screwed it up or not.

DIY Fly Fishing Box

Next was to do a little hacking on the fixed compartment dividers. I decided to remove all but one dividing wall of the box so that I would be left with only two compartments – one large and one small. It was purely a personal preference. Using a pair of tin snips and a sharp utility knife I removed the sections of dividers that I didn’t want. This took up the majority of the time and rightly so, I didn’t want to lose a finger.

DIY Fly Fishing Box

Once the box had been hacked to leave just the two compartments that I wanted, I decided to spray paint the bottom section to make it opaque and give it a little more of a custom look. I used a can of dark green Krylon spray paint that I had lying around in my garage from a previous geocaching project. Krylon paint is designed to bond with plastic really well and thin coats dry in about 10 minutes.

After 2-3 coats of spray paint and leaving the bottom section to thoroughly dry I installed a few pieces of carefully trimmed high-density foam (thanks Patrick) and my first little Tenkara project was done. All I needed to do was to add my spool of tippet, my Tenkara line, and a few spare dry flies. Sweet!

DIY Fly Fishing Case

  • Total cost: Under $2.00
  • Total Time: 50 minutes
  • Total weight: 1.5oz / 42g (minus lines and flies)

After taking the photos I changed the way I placed my flies into the foam, but other than that the fly box is good to go. I even had room for a small pair of line nippers next to the Tenkara spools in the large compartment – perfect.

Have you done and fishing related MYOG hacks? What do you think of my little project? Please leave a comment below.

(Visited 698 times, 1 visits today)
Be Sociable, Share!
  • JJ_Mathes

    Brian- nice job! It’s hard to beat a Plano box, they’re cheap and light and I’ve hacked plenty for various projects unrelated to fly fishing.

    Fly fishing shops in your area…hmmm I think there’s an Orvis store in Charotte, maybe start there and see if they’ll share other local store names with you. I know the guys at the Atlanta Orvis store are great when it comes to sharing info and hot fly fishing tips.

    I hiked across several good looking trout streams this week, really wished I had taken my rod…oh well, now I have a reason to hike it again. :)

    • http://www.briangreen.net Brian Green

      JJ, thanks. This was my first Plano box MYOG project but I can see that the box would be useful for so many other little projects. Are any of the ones you’ve done on your blog? I’d love to see.

      Also, can’t wait to read about your recent hiking adventures and see some photos on your blog – no pressure! :-)

      • JJ_Mathes

        Brian- no Plano boxes on my blog, they’re all used for other non hiking projects.

        Working on trip report and photos now, should have it up soon.

  • JERMM

    Brian- nice job! It’s hard to beat a Plano box, they’re cheap and light and I’ve hacked plenty for various projects unrelated to fly fishing.

    Fly fishing shops in your area…hmmm I think there’s an Orvis store in Charotte, maybe start there and see if they’ll share other local store names with you. I know the guys at the Atlanta Orvis store are great when it comes to sharing info and hot fly fishing tips.

    I hiked across several good looking trout streams this week, really wished I had taken my rod…oh well, now I have a reason to hike it again. :)

  • bfgreen

    JJ, thanks. This was my first Plano box MYOG project but I can see that the box would be useful for so many other little projects. Are any of the ones you’ve done on your blog? I’d love to see.

    Also, can’t wait to read about your recent hiking adventures and see some photos on your blog – no pressure! :-)

  • JERMM

    Brian- no Plano boxes on my blog, they’re all used for other non hiking projects.

    Working on trip report and photos now, should have it up soon.