Quick Callaway Re-Shaft Tips from Technical Director Jeff Summitt
Since I have had what seems as a rash of inquiries of late on re-shafting Callaway irons, I decided there must be more clubmakers that might not have experienced this repair situation.
One of the most confusing questions to answer is what is the hosel diameter of a Callaway iron, at least the non-Tour models like the X-22 Tour or X-Forged which are 0.355” tapered? This might sound a little confusing but they are neither a true 0.370” parallel nor 0.355” tapered bore, rather a modified bore.
If you remove the shaft, you will notice six slits running up the shaft tip. This is by design as Callaway starts out by using a 0.370” parallel tip shaft. Callaway’s hosels are slightly tapered so that when the shaft is inserted it pinches in the split shaft and forms a pseudo-mechanical lock.
Aside from trying to split the tip with a thin blade like they had done, there is an easy solution. You can run a 9.4mm drill bit into the hosel to accept a 0.370” shaft. One more thing, you will want to tip trim the shaft 1” less than called for (if at all possible). The reason this is necessary is to adjust for the deeper insertion depth caused by the thru bore design. Failure to do so will make the shaft play stiffer than designed.
The Callaway irons will also need special ferrules that are designed to fit the counter-bored hosel. The Callaway replacement ferrule will not only make the job easier, but provide that professional look.
You will also need plugs for the shaft for the models with the Bore Thru or Modified Bore Thru design. We do offer these but at this time they are non-catalog items. The code is TBP for graphite shafts 
and TBP1 for steel shafts and these tapered plugs come 25 to a pack ($2.75). After you have epoxied and hammered the pins in place, epoxy has dried and you have sanded them flush with the bottom of the sole, you can wipe them with acetone to get the nice factory finish.
Hopefully you have a learned a tip or two for that first time or your next time re-shafting a Callaway iron with the thru bore or modified thru bore design.
Buy 9.4mm Drill Bit $5.99 each
Buy Callaway Replacement Ferrrule $3.80 per dozen
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August 31st, 2009 at 9:40 pm
Awesome!!! I think lots of builders need to read this. Many have been asking about reshafting callaways iron and gotten half answers.
September 1st, 2009 at 7:46 am
great info. keep it up!
September 1st, 2009 at 10:58 am
Or the lazy mans way a 370 shaft will insert approx 24mm into the hosel. I have reshafted my own many times like this & never had a failure. Tips can be trimmed as standard without leaving the extension. On my own clubs I never bother to plug the open end as I alway cork the shaft end to prevent water entering. Obviously if for a customer it’s better to finish off in a proffesional manner
September 1st, 2009 at 11:09 am
this is very valuable info at no cost. thank you for this service.
September 1st, 2009 at 3:22 pm
Much easier than the way I did it. A friend asked if I could fix his bore-thru 8 iron. I had NO clue what I was getting into, but I fixed it by looking at what I pulled out. Dremel and cutting wheel, couple of practice cuts on an old shaft and I dove in head first. I got lucky figuring the shaft trim distance, cut the angle cut the slices, lined everything up applied the epoxy and drove the plug in, let it dry trimmed the plug, polished all, and my friend was overjoyed. Looked like a factory iron. However, the drill bit will be on order, got a feeling it will be much easier. Thanks for the lesson,the price was right and I am sure I will be able to use it in the future.
September 5th, 2009 at 7:32 pm
I just slice the shaft in half with my shaft cutting wheel, deep enough to match the callaway depth, install it with slice parallel to swing plane (that provides a lot more shaft material in contact with the hosel then original), install plug, grind the shaft to flush angle, sand and polish. Steel or Graphite, same treatment.
Never have had one come loose. I have had Callaway clubs brought to me for repair, graphite shaft twisted and crushed in the hosel from torque force at time of breakage in the hosel. Does not make sense to me. Maybe its convenient to factory installation system. Lucky for us nobody else has picked up on it.