Cray,
I worked with Matzuo engineers for the better part of two years to try and get their hooks right. The issue that we found was they were very inconsistant from one size to another. The 4/0 hooks I was using had a giant length from the bend to the eye of the hook. This forced the hook back in the cavity of the mold and often times didn't allow for a proper pour. To combat this, we ended up having to modify our molds to allow for the 4/0 hooks. Keep in mind that these were 5/8oz, 3/4oz, and 1oz jig heads. We used a drill bit slightly larger than the eye cavity and recessed both sides. This provided enough room to slide that longer hook bend forward and allow for the hook to sit properly in the mold. Unfortunately, the 5/8oz, and 1/2oz production molds we used had one more cavity (6) where as the 3/4 and 1oz had (5). In order to use the 4/0 hook in those smaller molds, we were forced to eliminate two of the cavities thus making each one a 3 cavity mold. The recess for one hook eye took way too much meat out of the mold which entered the ajoining cavity. To combat this, we switched those over to a 3/0 hook.
Then the fun began. The 3/0 hook bend didn't have the issues that the 4/0 hook did. They basically had the same leg length as a standard Mustad hook that the molds were designed for. What I ended up finding out was that all of these hooks were built on different machines. Some in totally different companies. The tolerances were all different. We began to look at other companies.
The sickle craze on the Detroit river hit a breaking point. Everybody had to have them. We sold 1000 sickle hook jigs for every 1 normal hook. Those numbers are actually generous. There was a downfall however. First, you gotta understand that the Detroit river is deep and fast with tons of snags. You might take one drift and snag up/break off, 5 times. Other times, you don't. Losing jigs is the name of the game. Which is good for the jig business!!!
With the standard hooks, they have bend and give to them. Oftentimes you could bend the hook and get the jig back. Bend her back in shape and carry on. This saved valuable retying time. Tournament fishing, we had no less than three rods sitting next to us and ready to go at any one time. The sickle hooks on the other hand are brittle. Brittle to a point that they brake before they bend. Again, guys didn't seem to care because they were needle sharp. The downside to this was the sharpening process. They are chemically sharpened. As a result, you cannot touch one up with a file to make it sharp again. If it is dull, it is junk. I also believe the chemical process contributed to the weakness of the hooks.
Last year, we pretty muched provided a game changer to the local industry. Everybody and their brother wanted RED sickle hooks. What we found in our testing was that the standard Broze and black chrome hooks were NOT prone to as much breaking as the red. What we gathered was the anodizing process used to dye those hooks along with the chemical process used to sharpen the red ones greatly reduced the overall strength of the hook.
My busness was to provide customers what they wanted and needed. At the same time, unlike other companies, we actually tested our products. Many color combinations hit the cutting room floor long before they were ever introduced to the public. I provided this feedback to our customers and, as a result, they begain to see the value and benefit. This year, I notice many of our competitors have gone to doing the same things that made me a river name! Attention to detail, removing paint from the eyes, actually baking their jigs to harden them!!! The list goes on and on. The majority of these companies are using the color combos we created!