Opinion & Analysis
Avoid these 5 club building disasters

I’ve been fitting and building golf clubs for more than 15 years, and in that time I’ve seen a lot of really poor workmanship — stuff that would make most GolfWRXers cringe. But like anyone who ever did anything new, I didn’t start being naturally good at putting together clubs. It took a lot of time, ruined components, and trial and error to get where I am today.
I believe my attention to detail now stems from the fact that my dad was a machinist by trade, and anytime we ever worked on something together his attitude was to take your time and do it right the first time. My dad’s approach always had an impact on me, because I feel that if you do something right — even when it takes a bit longer — the job is not only more satisfying, but also makes things work better and last longer.
The goal with this article is to help WRXers avoid the most common mistakes and assumptions in club building that lead to broken or ruined clubs, as well as real danger.
Over-prepping a graphite shaft

The shaft on the left has been prepped properly. The one of the right, which has noticeable taper, shows signs that layers of graphite have been removed.
This happens far more than it should, and can ruin an expensive new shaft purchase. To prepare a shaft properly for installation, you only need to remove enough of the paint to make sure that the epoxy adheres to the graphite. This is also true for the inside of the hosel.
Be careful to remove residual epoxy, dirt or rust (common with forged carbon steel club heads that have been sitting around for a while), or some type or solvent like the one used to put on grips, as it can cause of bond to break down very quickly. A proper reaming tool, a wire brush and some compressed air (either a small can or a large air compressor) can make cleaning simple, and prevent a golf club from falling apart.
UPDATE: Over prepping specifically applies to shafts that are designed to go into parallel heads and is especially important for 335 shafts with less material at the tip going into drivers and fairway woods. For information on how to properly taper a shaft to go into a tapered head, check out the video below:
Overheating a Shaft When Pulling it

This is what happens to a graphite shaft when overheated, and the resin holding the graphite sheets together breaks down. It’s not always as noticeable, but if the shaft starts to fray it means the bonds have been compromised and it’s more likely to fail.
Overheating a shaft when pulling it is another common mistake that can result in ruining a golf shaft. It also highly increases the chance of breakage. There are quite a few methods I’ve learned over the years to remove a shaft from a club head, from heat guns to large propane torches, but personally I find that using a small butane torch with a regulator for graphite offers the best results. It allows a club builder to easily control and focus the heat only where it’s needed. Bigger torches are fine for iron heads, as long as you don’t damage any plastic badges in the cavity or materials in slots around the head.
One of the best advances in club technology has been the invention and mass adoption of adjustable hosels. They not only help golfers adjust the loft, lie and face angle of club heads, but have also greatly decreased the need to pull shafts. So as long as a golfer is staying with the same metal wood manufacturer, they can usually test several different clubs heads with the same shaft, or vice versa — several different shafts with the same clubhead.
That being said, one of the most important tools that any hobbyist club builder should have or have access to is a high-quality shaft puller. It’s a necessary tool for anyone who wants to do repairs and helps prevent damage to a shaft while pulling it. The more linear pressure that can be applied to the clubhead, and the less heat used to break down the epoxy, the better. It makes sure both the shaft and the head are reusable in the future. For steel shafts, you can use a bit more heat, and twisting isn’t a problem. Again, with increased heat, be careful not to damage any of the badging, or permanently discolor an iron head.
Botching a Grip Installation

Using calipers and two-sided tape, you can replicate the taper of shafts to makes every grip feel exactly the same size in your set.
This one seems simple, but when really getting down to professional level detail, it is quite important. We ALL have a preference and different opinion of what feels good in a golf grip, as well as different sensitivities. For example, we all have the ability to figure out what apple is bigger, even if blindfolded because over time we all develop brain function to understand shapes and sizes. This also applies to grips. If you use the same grips on your 13 clubs, you could potentially have 4-5 different final sizes depending on how many different types of shafts you use, because many shafts have different butt diameters.
Some shafts have larger butt diameters, while others taper faster than others. That’s why it’s very important to own a quality set of vernier calipers, and know how to properly use them. It’s also the same for putters, since many putter shafts are smaller in diameter. I have lost count of how many times I’ve had people bring me, putters, where the bottom half of the grip is twisting and turning because the installer never paid attention to the interior diameter of the grip, the exterior diameter of the shaft, and how it changed from top to bottom.
Using epoxy that’s doomed to fail
I’m a bit of a physics nerd and garage engineer, so this is one of those topics that goes beyond just the physical aspects of club building and into the realm of chemistry.
Here comes my nerd-out moment: In the simplest of explanations for a 0.335-inch driver hosel with an insertion depth of 1.25 inches, the amount of calculated surface area the epoxy can bond between the shaft and the head using the internal dimensions of the head is 1.49 square inches. That’s not a whole lot of area when you consider the centrifugal force being applied to a driver head traveling at 100 mph, and then the forces of torque that also come into play when a shot is struck.
In a PERFECT world, almost zero torque is applied to a shaft when a shot is hit on the center of gravity (CG) of the club head, perfectly aligned with the center mass of the ball, while traveling in the intended direction. This is vectors 101 of physics. Unfortunately, almost every single shot is NOT hit like that, and this is where the epoxy bond is put under the most amount of stress. Lap shear strength of epoxy goes beyond me, but it proves that building a golf club is not just cut and glue after all.
Note: For those of you curious, the most popular epoxies are rated for 4500 psi.
As far are actually working with epoxy, first things first. Always check to see if the epoxy has a best-before date (yep, just like milk). Also, never store epoxy in direct sunlight. If you are using epoxy from a tube in a dispensing gun, you are using what is an almost foolproof method. Plunge out the necessary amount, mix for about a minute (mix! don’t whip), and remember, the less air that gets into the epoxy the better. If air gets in and the epoxy cures with bubbles in it, then you end up with a club that will often “creak.”
For those using two parts in larger bottles, the best way to ensure proper ratios is to pay attention to the weight ratio rather than volume. This isn’t arts and crafts; it’s chemistry, so by using the weight to calculate the ratio you will get the right amount of each part every time, and help decrease the risk of failure down the road. If you have mixed a larger batch and plan on building quite a few clubs at a time, you really have to pay attention to the consistency and viscosity as time goes on. You don’t want to glue a club head with epoxy that has started to set.
Turning an Extension into a Shank
This is one of those subjects I don’t even like to talk about. I very much dislike using extensions when building clubs, especially clubs with graphite shafts. Going back to my “do-it-right-the-first-time” mentality, extensions are a Band-Aid fix to a problem that requires surgery. They also counter-balance the club, and by their very nature create a weak point because of the small wall thickness at the butt end of a shaft. The only clubs I don’t mind extending on a regular basis are putters since they are never put under the same level of stress as a club being swung at full speed. I also never extend a club more than 1 inch, because I have been witness to horror stories of clubs that have been overextended that not only break but rip through the grip and cut people’s hands very badly.
If you are going to extend a club, it’s important to make sure the fit is very snug and doesn’t cause the extension to lean in any direction. It’s also best to have the epoxied extension cure with the club on its side to avoid an excess epoxy from running down the shaft and breaking off and causing a rattle.
Opinion & Analysis
The 2 primary challenges golf equipment companies face

As the editor-in-chief of this website and an observer of the GolfWRX forums and other online golf equipment discourse for over a decade, I’m pretty well attuned to the grunts and grumbles of a significant portion of the golf equipment purchasing spectrum. And before you accuse me of lording above all in some digital ivory tower, I’d like to offer that I worked at golf courses (public and private) for years prior to picking up my pen, so I’m well-versed in the non-degenerate golf equipment consumers out there. I touched (green)grass (retail)!
Complaints about the ills of and related to the OEMs usually follow some version of: Product cycles are too short for real innovation, tour equipment isn’t the same as retail (which is largely not true, by the way), too much is invested in marketing and not enough in R&D, top staffer X hasn’t even put the new driver in play, so it’s obviously not superior to the previous generation, prices are too high, and on and on.
Without digging into the merits of any of these claims, which I believe are mostly red herrings, I’d like to bring into view of our rangefinder what I believe to be the two primary difficulties golf equipment companies face.
One: As Terry Koehler, back when he was the CEO of Ben Hogan, told me at the time of the Ft Worth irons launch, if you can’t regularly hit the golf ball in a coin-sized area in the middle of the face, there’s not a ton that iron technology can do for you. Now, this is less true now with respect to irons than when he said it, and is less and less true by degrees as the clubs get larger (utilities, fairways, hybrids, drivers), but there remains a great deal of golf equipment truth in that statement. Think about it — which is to say, in TL;DR fashion, get lessons from a qualified instructor who will teach you about the fundamentals of repeatable impact and how the golf swing works, not just offer band-aid fixes. If you can’t repeatably deliver the golf club to the golf ball in something resembling the manner it was designed for, how can you expect to be getting the most out of the club — put another way, the maximum value from your investment?
Similarly, game improvement equipment can only improve your game if you game it. In other words, get fit for the clubs you ought to be playing rather than filling the bag with the ones you wish you could hit or used to be able to hit. Of course, don’t do this if you don’t care about performance and just want to hit a forged blade while playing off an 18 handicap. That’s absolutely fine. There were plenty of members in clubs back in the day playing Hogan Apex or Mizuno MP-32 irons who had no business doing so from a ballstriking standpoint, but they enjoyed their look, feel, and complementary qualities to their Gatsby hats and cashmere sweaters. Do what brings you a measure of joy in this maddening game.
Now, the second issue. This is not a plea for non-conforming equipment; rather, it is a statement of fact. USGA/R&A limits on every facet of golf equipment are detrimental to golf equipment manufacturers. Sure, you know this, but do you think about it as it applies to almost every element of equipment? A 500cc driver would be inherently more forgiving than a 460cc, as one with a COR measurement in excess of 0.83. 50-inch shafts. Box grooves. And on and on.
Would fewer regulations be objectively bad for the game? Would this erode its soul? Fortunately, that’s beside the point of this exercise, which is merely to point out the facts. The fact, in this case, is that equipment restrictions and regulations are the slaughterbench of an abundance of innovation in the golf equipment space. Is this for the best? Well, now I’ve asked the question twice and might as well give a partial response, I guess my answer to that would be, “It depends on what type of golf you’re playing and who you’re playing it with.”
For my part, I don’t mind embarrassing myself with vintage blades and persimmons chasing after the quasi-spiritual elevation of a well-struck shot, but that’s just me. Plenty of folks don’t give a damn if their grooves are conforming. Plenty of folks think the folks in Liberty Corner ought to add a prison to the museum for such offences. And those are just a few of the considerations for the amateur game — which doesn’t get inside the gallery ropes of the pro game…
Different strokes in the game of golf, in my humble opinion.
Anyway, I believe equipment company engineers are genuinely trying to build better equipment year over year. The marketing departments are trying to find ways to make this equipment appeal to the broadest segment of the golf market possible. All of this against (1) the backdrop of — at least for now — firm product cycles. And golfers who, with their ~15 average handicap (men), for the most part, are not striping the golf ball like Tiger in his prime and seem to have less and less time year over year to practice and improve. (2) Regulations that massively restrict what they’re able to do…
That’s the landscape as I see it and the real headwinds for golf equipment companies. No doubt, there’s more I haven’t considered, but I think the previous is a better — and better faith — point of departure when formulating any serious commentary on the golf equipment world than some of the more cynical and conspiratorial takes I hear.
Agree? Disagree? Think I’m worthy of an Adam Hadwin-esque security guard tackle? Let me know in the comments.
@golfoncbs The infamous Adam Hadwin tackle ? #golf #fyp #canada #pgatour #adamhadwin ? Ghibli-style nostalgic waltz – MaSssuguMusic
Podcasts
Fore Love of Golf: Introducing a new club concept

Episode #16 brings us Cliff McKinney. Cliff is the founder of Old Charlie Golf Club, a new club, and concept, to be built in the Florida panhandle. The model is quite interesting and aims to make great, private golf more affordable. We hope you enjoy the show!
Opinion & Analysis
On Scottie Scheffler wondering ‘What’s the point of winning?’

Last week, I came across a reel from BBC Sport on Instagram featuring Scottie Scheffler speaking to the media ahead of The Open at Royal Portrush. In it, he shared that he often wonders what the point is of wanting to win tournaments so badly — especially when he knows, deep down, that it doesn’t lead to a truly fulfilling life.
View this post on Instagram
“Is it great to be able to win tournaments and to accomplish the things I have in the game of golf? Yeah, it brings tears to my eyes just to think about it because I’ve literally worked my entire life to be good at this sport,” Scheffler said. “To have that kind of sense of accomplishment, I think, is a pretty cool feeling. To get to live out your dreams is very special, but at the end of the day, I’m not out here to inspire the next generation of golfers. I’m not out here to inspire someone to be the best player in the world, because what’s the point?”
Ironically — or perhaps perfectly — he went on to win the claret jug.
That question — what’s the point of winning? — cuts straight to the heart of the human journey.
As someone who’s spent over two decades in the trenches of professional golf, and in deep study of the mental, emotional, and spiritual dimensions of the game, I see Scottie’s inner conflict as a sign of soul evolution in motion.
I came to golf late. I wasn’t a junior standout or college All-American. At 27, I left a steady corporate job to see if I could be on the PGA Tour starting as a 14-handicap, average-length hitter. Over the years, my journey has been defined less by trophies and more by the relentless effort to navigate the deeply inequitable and gated system of professional golf — an effort that ultimately turned inward and helped me evolve as both a golfer and a person.
One perspective that helped me make sense of this inner dissonance around competition and our culture’s tendency to overvalue winning is the idea of soul evolution.
The University of Virginia’s Division of Perceptual Studies has done extensive research on reincarnation, and Netflix’s Surviving Death (Episode 6) explores the topic, too. Whether you take it literally or metaphorically, the idea that we’re on a long arc of growth — from beginner to sage elder — offers a profound perspective.
If you accept the premise literally, then terms like “young soul” and “old soul” start to hold meaning. However, even if we set the word “soul” aside, it’s easy to see that different levels of life experience produce different worldviews.
Newer souls — or people in earlier stages of their development — may be curious and kind but still lack discernment or depth. There is a naivety, and they don’t yet question as deeply, tending to see things in black and white, partly because certainty feels safer than confronting the unknown.
As we gain more experience, we begin to experiment. We test limits. We chase extreme external goals — sometimes at the expense of health, relationships, or inner peace — still operating from hunger, ambition, and the fragility of the ego.
It’s a necessary stage, but often a turbulent and unfulfilling one.
David Duval fell off the map after reaching World No. 1. Bubba Watson had his own “Is this it?” moment with his caddie, Ted Scott, after winning the Masters.
In Aaron Rodgers: Enigma, reflecting on his 2011 Super Bowl win, Rodgers said:
“Now I’ve accomplished the only thing that I really, really wanted to do in my life. Now what? I was like, ‘Did I aim at the wrong thing? Did I spend too much time thinking about stuff that ultimately doesn’t give you true happiness?’”
Jim Carrey once said, “I think everybody should get rich and famous and do everything they ever dreamed of so they can see that it’s not the answer.”
Eventually, though, something shifts.
We begin to see in shades of gray. Winning, dominating, accumulating—these pursuits lose their shine. The rewards feel more fleeting. Living in a constant state of fight-or-flight makes us feel alive, yes, but not happy and joyful.
Compassion begins to replace ambition. Love, presence, and gratitude become more fulfilling than status, profits, or trophies. We crave balance over burnout. Collaboration over competition. Meaning over metrics.
Interestingly, if we zoom out, we can apply this same model to nations and cultures. Countries, like people, have a collective “soul stage” made up of the individuals within them.
Take the United States, for example. I’d place it as a mid-level soul: highly competitive and deeply driven, but still learning emotional maturity. Still uncomfortable with nuance. Still believing that more is always better. Despite its global wins, the U.S. currently ranks just 23rd in happiness (as of 2025). You might liken it to a gifted teenager—bold, eager, and ambitious, but angsty and still figuring out how to live well and in balance. As much as a parent wants to protect their child, sometimes the child has to make their own mistakes to truly grow.
So when Scottie Scheffler wonders what the point of winning is, I don’t see someone losing strength.
I see someone evolving.
He’s beginning to look beyond the leaderboard. Beyond metrics of success that carry a lower vibration. And yet, in a poetic twist, Scheffler did go on to win The Open. But that only reinforces the point: even at the pinnacle, the question remains. And if more of us in the golf and sports world — and in U.S. culture at large — started asking similar questions, we might discover that the more meaningful trophy isn’t about accumulating or beating others at all costs.
It’s about awakening and evolving to something more than winning could ever promise.
Jim D.
Aug 15, 2019 at 7:59 am
I appreciate your work and thoughtful information. What are your thoughts regarding the use of “bonding beads” in the epoxy mix. When applied to the shaft the beads are intended to assist in centering the shaft in the hosel when reshafting. I’d be interested in your opinion and your experience regarding this process.
Thanks!!!!
Jim
Locode
Jul 18, 2016 at 2:40 pm
Great article. I extended 2 sets of my own irons a full 2 inches and never had a problem with them.
One point. A CREEK is a narrow running waterway, bigger than a stream and smaller than a river.
A CREAK is that sound you hear from your golf club for whatever technical reason.
Ken Boucher
Apr 30, 2019 at 4:45 pm
If you extended your clubs 2″ you are begging for trouble. Also the swing weight would be extremely high,not good.
Ryan
Jun 30, 2016 at 12:39 pm
A good rule for hobbyists to follow for prepping graphite shafts is to mask off where you want to prep and then take a box cutter and start at the line of the tape and “scrape” down towards the tip of the shaft. You will never damage the shaft and a good bond will form with the epoxy.
Other issues I run into with “rookies” is not cleaning out the hosel properly. Prep is the key to building quality golf clubs that don’t fail. Also spend the extra 20 seconds and really mix the epoxy well. Once mixed, throw a heat gun on the epoxy for about 5-10 seconds and “heat cure” it. It will make a stronger bond.
And to Charlie above, typically when you add extensions it will zero out to a certain extent because the extension weighs more than the amount of shaft that was removed. The problem is the static weight of the club is heavier. I follow the rule of building a club off a 50g grip and building to that. I also don’t like using extensions and rarely ever use them. About 1/2″ and down will decrease the SW and anything over 1/2″ will increase the SW. I build clubs to 10 points higher without the grip and then install the grip.
Sam Snood
Jun 30, 2016 at 10:58 am
I always thought the creaking/squeaking sound was the ferrule moving slightly.
John Grossi
Jun 30, 2016 at 9:02 am
I have owned 2 adjustable drivers, a cobra amp and a callaway xr, and they both creek. Neither ever worked on so must be the factory glue. Very impressed with your knowledge and willingness to share it. Thanks
Golfrnut
Jun 30, 2016 at 3:31 pm
Many of the adjustable heads are creaking due to the mating surface of the adapter and socket rubbing together. It’s not always an issue with the epoxy bond. Something a little WD-40 wiped on the adapter or a light coat of graphite paste can remedy it a lot of times.
graymulligan
Jun 29, 2016 at 9:49 pm
Thanks for a really well written, simple, concise article on something that might help a bunch of folks. It’s funny, I never really equated the idea of bubbles and creaking (“creek”…lol), but it makes a ton of sense, and is something I’ll make sure to pay more attention to going forward.
BIG STU
Jun 29, 2016 at 5:29 pm
Good article I have been building and tinkering with clubs over 30 years. As Brian stated I have learned from past mistakes. Maybe giving heed to the advice in this article will keep some folks from learning from the school of hard knocks.
Bert
Jun 29, 2016 at 3:27 pm
Great article thanks! Been tinkering for years and improved my techniques the hard way. Many bad results can challenge ones methods, perhaps saying “why did I do that”?
Bobalu
Jun 29, 2016 at 9:42 am
Good to see the first (?) club building article on GOLFWRX!
Tom
Jun 29, 2016 at 10:59 am
agreed.
peter collins
Jun 29, 2016 at 2:08 pm
here here, more club building topics please.
Scott
Jun 29, 2016 at 2:55 pm
+1
Smith
Jun 29, 2016 at 9:09 am
I was in a couple weeks ago and Ryan did a re-shaft/hotmelt on a Cobra Bio Cell fairway of mine. His work is second to none! If you’re in the Toronto area (or near any other MG locations), you’re honestly doing a disservice having club work done anywhere else.
M Sizzle III
Jun 29, 2016 at 9:06 am
I’ve been to Modern Golf’s facility in Toronto, Canada and it is amazing. Like a laboratory! All should visit if they have a chance. No, I don’t work there nor do I have a relationship with the company.
Charlie
Jun 29, 2016 at 8:35 am
I’d put not checking swingweight up there as well. You put your extensions from #1 on a club and you’ll be sitting at an E5.