Zillion handle nuts continue to strip, what’s wrong?

[Bandersnatch]

I have a number of reels on which I swap out the handles for the 100mm Daiwa paddle handle. All of them work without issue except for this one JDM Zillion in particular. I’m aware that the bits can strip easily if over-tightened and simply assumed that’s what I did. However, after using several new nuts carefully tightened down, as soon as I set the hook, the nut gets loose and the handle almost falls off. Is it possible I’m missing a piece after disassembling? Is it possible the main handle shaft thread is stripped?

I’m considering sending this to someone, including DVT, but this shouldn’t be this complicated.

What are your thoughts?

[Kev-mo]

If nothing is stripped perhaps mis manufactured/tolerances off? Or something along those lines.

[A kid from Canada]

Are you using a nut retainer? 

[garroyo130]

A tiny bit past hand tight with retainer over the top ... sounds like you dont have the retainer?

[webertime]

Maybe stripped the drive shaft?

[Delaware Valley Tackle]

It’s common for stripped or cross threaded nut to damage the shaft threads. Without seeing it that’s my guess. The hook set part is coincidental. Make sure the retainer is installed. Let me know if you want me to take a look. 

[bulldog1935]

Except the Daiwa nut is aluminum alloy and the main shaft threads are brass.  

While the brass threads could be bunged up, you could chase the main shaft threads with a stainless M8 (fine thread) then try a new handle nut.  

Not cheap, but KDW makes titanium handle nuts - these are go to for me in the salt. 

And yes, the whole point of the retainer is to lock the nut from backing off.  

[Bandersnatch]

I used the plastic retainer with the old orginsl

nut. This replacement came with a metal retainer in which I used. First hookset the handle came loose. 

[bulldog1935]

Daiwa picked both plastic and alloy handle nuts to protect the mainshaft threads - too easy to cross-thread on the square-end shaft, 

On Zillion, it's complicated by the springy star drag detente-clicker, which acts like an accordion and pushes the hollow star drag and handle outward.  It's possible you could cross thread the handle nut and everything feel tight and ok, then everything flops off the main shaft when you're under crank load.  

 

Tightening the handle nut should give you 5 full turns - if it binds up in fewer, it's cross-threaded.  

[Delaware Valley Tackle]

It’s very easy to cross  handle nuts. They should start easily and turn by hand initially. It happens. We’ll figure it out 

[Bandersnatch]

The red nut is a replacement but. I do see some damage to the thread at the 5th thread in on the one side. Do you think this is enough to need to replace the main shaft ? Would using a new stainless open ended m8xmm nut clean up the threads enough ? It was suggested to potentially try a stainless or titanium nut? 
 

Either way. I’d like to get it resolved without putting too much into it if possible. At the same time. My flip pitch handle will be here tomorrow and my plan for this reel was putting as much torque on it frogging to find its limits. I certainly need to have the confidence that the reel handle will hold up. 

It’s worth noting that the original plastic nut retainer wouldn’t fit properly with this replacement nut. That’s why I ordered two more zillion nuts from the tackle trap. I also had some inkling that the red retainer was so thin that almost sat under the nut allowing the nut to spin under torque. 
 

I appreciate all of your opinions. 

[waymont]

11 hours ago, Bandersnatch said:

The red nut is a replacement but. I do see some damage to the thread at the 5th thread in on the one side. Do you think this is enough to need to replace the main shaft ? Would using a new stainless open ended m8xmm nut clean up the threads enough ? It was suggested to potentially try a stainless or titanium nut? 
 

Either way. I’d like to get it resolved without putting too much into it if possible. At the same time. My flip pitch handle will be here tomorrow and my plan for this reel was putting as much torque on it frogging to find its limits. I certainly need to have the confidence that the reel handle will hold up. 

It’s worth noting that the original plastic nut retainer wouldn’t fit properly with this replacement nut. That’s why I ordered two more zillion nuts from the tackle trap. I also had some inkling that the red retainer was so thin that almost sat under the nut allowing the nut to spin under torque. 
 

I appreciate all of your opinions. 

Looks like to stripped the threads, and the that's why your handle is getting loose.

[txchaser]

I have a tat sv that doesn't have the retainer and it does the same thing. Nut is just constantly loose.

 

I bet when you have a nut that fits the retainer it goes away, even with the threads torn up a little it won't be able to back out unless it's just totally stripped out. And the load bearing part of the handle is the rectangular cutout and the similarly shaped part of the shaft. So I think the nut's just holding it all together, and making something for the drag star (through a couple of parts) to push against. 

Anyway I don't think threads are making it fall off like that - the one I have has great threads but I have to tighten it by hand every few casts. It's on the desk now waiting for me to get off my tail and order a replacement retainer.