Thread for large hair bugs or other high tensile strength uses
Brand
Denier
Breaking Strength
UTC 280
280 Denier
70 OZ
Uni-Cord 7/0
100GSP
128OZ
Kevlar (all brands)
200
128OZ
Danville A Monocord
N/A
52OZ
Gudebrod G
N/A
59OZ
Danville Flat Waxed Nylon
223
67OZ
Danville Flymaster +
237
61OZ
Uni A Nylon
N/A
44OZ
Uni A+
N/A
60OZ
Uni Big Fly
400
100OZ
Monofilament thread
Diameter
Breaking strength
.004
160Z
006 - .007
36 - 440Z
* This chart is a list of the options sold by various thread wholesalers. Some information is derived from manufacturers' data, and some from personal experience. The thread comparison chart was compiled by verifying the information supplied by the thread suppliers, conducting thread breaking strength test with a Chatillion scale, using loupes with 8X - 20 X magnification, feel, and tying experience.
True diameter comparisons are very difficult with thread because it compresses when a standard micrometer is applied to it. I have tried to mic thread, and my results varied as much as .003" on a single thread. That is too much of a variable to me.
The most accurate of available measurements is denier. This is the textile industry standard. A denier equals the gram weight of 9,000 meters of thread. Since nylon and polyester are comparable strengths and weights, denier is a fairly accurate comparison.
Wapsi was the first to actively promote a denier thread designation. They conducted tests of various threads both in-house and at a private lab. They gave me permission to use the results in this article.
GSP is lighter in weight than other materials, so the denier weight is lighter than the strength and appearance would indicate. Twisted ply thread on the other hand, seems to be a heavier denier for a given strength. From this I conclude that twisting fibers adds more weight within a given length of thread, but it does not add strength.
Jean-Guy Cote of Uni also provided denier and breaking strength results for his thread, and Gudebrod also supplied breaking strengths. On threads where the denier was not supplied, I compared them against threads of known denier by visually inspecting at magnification, by tying with them, and using a non-caliper tippet gauge.
The tippet gauge was a slot type made by Gage.It. On this tippet gauge, you push the material into the slot until it touches the sides. Thread compresses so I didn't use this for accurate measurements, but I used it to get a rough idea of comparative thickness. I did this by pulling the thread into the gauge six times and comparing the average. While compiling this information, I tied the same fly, in the same size with various threads. I felt this would give me a real life comparison. Mono thread was measured with a micrometer. Both Gudebrod and Uni have a larger mono thread. I didn't have samples before I finished the article so they are not on the charts
While conducting breaking strength test, it occurred to me "if nylon and polyester are comparable strengths, breaking strength should give a fair approximation of thread sizes." Above I list thread by types of use, and my opinion of diameters within a category. Even among the best thread producers, thread strengths and diameters vary. These charts were designed to give you a fair comparison and not exact scientific results.
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