Foam Popper Tying Instruction
The hardest part may be getting the poly foam cut to the correct sizes. If anyone knows of ready made cut foam sources, please let us know. We typically get sheets of the foam and cut it with a band saw. Experiment until you get the size and proportion that rides correctly in the water.
Gluing Tip: Take a tip from the orthopedic surgeon who knows pressure applied to any glue or cementing process is critical to eliminating air bubbles and dramatically increasing the bonding process. Always apply pressure when possible as suggested in the steps below.
Hooks: Kinked Popper Hook Mustad 33903 sizes #6 - #2 for most smallie situation. Size #4 is the best all around size. Hackle: Colored Saddle hackle Eyes: Any commercially available fly eyes. Wings or Tail: Marabou, Bucktail, or Saddle Hackle, flashabou optional.
Step One: It is critical to get a precise center cut, about 1/8 to 1/4 inch deep into the bottom of the body. Since we know of no commercially available precut bodies, you must use a razor blade and simply eyeball it.
The cut need not be too deep since you want the hook shaft to be right near the bottom of the body. A mat knife or carpet cutting knife can be used, as well. 
Step Two: Wrap thread (color is your choice) around the shaft of the hook. Pinch the barb down now if not pre-pinched. Apply Zap-A-Gap to the thread.
Spread open the sliced area and mount the popper body on the shaft. You only have a few seconds to orient it properly so make sure you check for the proper depth - both fore and aft on the shaft.
 Step Three: Take a moment to squeeze the foam together applying pressure to close the gap under the hook as best you can. Flip the popper upside down or rotate on your vise and apply more Zap-A-Gap to the seam. This is optional and not used by all tiers. This really helps solidify the fly to the hook. Next apply the eyes by rotating the body on its side and applying the eye with a drop of glue, using a tweezers or hemostat. Again, finger pressure after fast-dry glue application will always increase the bond.
Step Four: Apply tail material which can be just about anything. I like marabou because of the sexy action it gives to the fly. Don’t make it too long or it will foul on the hook shaft. The length of the tail should be about the length of the straight part of the hook shaft. You can add flashabou or tinsel if you like. I don’t believe it is necessary, some will disagree.
Step Five: Apply hackle palmering forward. You can throw a couple of half hitches or whip finish to end just behind the back of the body. A drop of head cement will only help.
That’s it! They are so fast to tie. You can knock out twenty in two hours. Experiment with sizes and colors as usual. White, Yellow and Greens are always mainstays.
Oh by the way, don’t completely abandon you cork, wood or hairpoppers. There are many a day when other materials will shine above these Sponge Bobs. But I must admit, they are dynamite and should be part of your arsenal anytime you are on smallie waters. 
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