Big Jon Schematics

In the precise world of controlled-depth trolling, where presenting a lure at a specific, repeatable depth is the paramount factor for success, Big Jon downriggers have established themselves as a benchmark for durability, innovation, and performance. These devices are far more than simple winches; they are sophisticated fishing systems engineered to give anglers ultimate command over their subsurface presentation. A deep dive into their mechanical and electrical architecture reveals a commitment to robust materials, thoughtful design, and a range of models built to withstand the harshest aquatic environments.

The Core Principle: Precision Depth Control

A downrigger’s fundamental purpose is to deploy a heavy weight, or “cannonball,” on a cable to a precise depth, with the fishing line attached via a line release. This allows light-tackle lures to be fished at extreme depths without requiring an excessive amount of weight on the fishing line itself. When a fish strikes the lure, the line pulls free from the release, and the angler can fight the fish directly on their rod and reel, unencumbered by the heavy cannonball. Big Jon’s engineering is focused on perfecting every aspect of this process, from deployment and retrieval to rod management and durability.

Construction and Materials: The Foundation of Durability

Big Jon’s reputation is built upon a foundation of superior materials. The main components, including the boom, pedestal, and frames, are typically constructed from aircraft-grade aluminum. This material is chosen for its exceptional strength-to-weight ratio, allowing for a rugged build that is not excessively heavy. To combat the corrosive effects of both freshwater and saltwater environments, this aluminum is treated with a multi-stage finishing process. This often includes anodizing, which creates a hard, durable, and corrosion-resistant oxide layer on the surface of the aluminum, ensuring longevity and a lasting finish.

Critical hardware, fasteners, and internal components like drive shafts and gears are made from stainless steel. This ensures that the parts subjected to the highest stress and the most direct exposure to water are impervious to rust and corrosion, maintaining smooth operation for the life of the unit.

Mechanical Systems: A Tale of Two Designs

Big Jon downriggers are broadly categorized into two distinct operational designs: manual and electric. Each possesses a unique mechanical system tailored to its method of operation.

1. The Manual Downrigger: Precision Clutch Control

The heart of a Big Jon manual downrigger is its sophisticated, one-way clutch system. This is not a simple free-spooling winch; it is a finely tuned mechanism designed for controlled, one-handed operation.

The Clutch Mechanism: The system is built around a series of clutch discs. When the handle is cranked forward to retrieve the weight, these discs are fully engaged, providing a solid, direct drive to the spool. The ingenuity lies in the descent. By turning the crank handle backward, the angler does not put the reel into a wild free-spool. Instead, this reverse motion slightly disengages the clutch discs, allowing the weight to descend under its own power. The degree to which the handle is turned backward dictates the amount of pressure on the clutch discs, and therefore, the speed of the cannonball’s descent. This allows for incredibly precise “feathering” of the weight to a target depth shown on the mechanical line counter.
The One-Way Lock: An integral part of this system is a one-way bearing or pawl that prevents the handle from spinning backward under the load of the cannonball. This is a critical safety and convenience feature. An angler can stop the descent at any point simply by letting go of the handle, and the clutch system will hold the weight securely in place.
The Drivetrain: A simple but robust gear train, typically made of stainless steel, translates the power from the crank handle to the spool. The gear ratio is optimized to provide a good balance between retrieval speed and cranking power, making it manageable to lift heavy cannonballs from significant depths.

2. The Electric Downrigger: Automated Power and Precision

Big Jon’s electric models replace manual effort with a powerful and reliable electrical system designed for convenience and heavy-duty use.

The Motor and Gearbox: At the core is a sealed, high-torque 12-volt DC electric motor. This motor is chosen for its power and low current draw, minimizing the drain on the boat’s battery. The motor drives a sealed gearbox containing a series of reduction gears. This gearbox multiplies the motor’s torque, providing the immense power needed to lift heavy cannonballs (up to 20 pounds or more) at impressive speeds, often well over 100 feet per minute.
The Electrical System: The system includes a power cable with a circuit breaker for overload protection. On the unit itself, a weatherproof two-position switch allows for “Up” and “Down” operation. For added safety and convenience, many models incorporate an auto-stop feature. This is achieved via a conductive stop-bead on the downrigger cable. When the weight is fully retrieved, this bead makes contact with a sensor on the pulley at the end of the boom, completing a circuit that automatically cuts power to the motor, preventing the cannonball from crashing into the unit.
The Clutch/Brake: Even in the electric models, a clutch system is essential. It prevents catastrophic gear damage if the cannonball snags on the bottom. The clutch is designed to slip under extreme load, allowing the cable to pay out and preventing the boom from bending or the motor from burning out.

Common Features Across the Model Lines

Beyond the core retrieval system, several key features are hallmarks of Big Jon design.

Depth Counter: A sealed, mechanical, three-digit depth counter is standard. It measures cable deployment in feet, driven by a small gear that interfaces with the main spool. Its accuracy is vital for implementing precise trolling patterns.
The Boom: The aluminum boom is a critical component, available in various lengths from two to six feet. Longer booms provide greater separation between the cannonball and the boat, reducing the chance of lines tangling with the propeller, especially during turns. Many feature a telescoping design for easy storage.
The Swivel Base: An optional but highly recommended feature is the 360-degree swivel base. This allows the downrigger to be rotated inboard for easier rigging, and then locked into multiple positions for fishing. This is accomplished with a spring-loaded locking pin that engages with a series of machined holes in the base plate.
The Rod Holder: Big Jon rod holders are known for their robust, deep-tube design. They securely hold the rod, positioning it for optimal viewing and easy removal. They are often adjustable, allowing the angler to change the angle of the rod both horizontally and vertically to fine-tune the presentation.

Exploring the Big Jon Models

Big Jon offers a range of models, each with a feature set designed for a particular type of angler or fishing application.

Manual Series (e.g., Gadabout, Runabout): These are the entry points, offering the core Big Jon durability and clutch system in a compact, lightweight, and affordable package. They are ideal for smaller boats, occasional use, or for anglers who prefer the simplicity of manual operation.
Sportsman Electric: This model represents the entry into the electric lineup. It provides the convenience of powered retrieval in a durable, no-frills package, making it one of the most popular choices for anglers looking to upgrade from manual downriggers.
Pro Tournament: As the name implies, this model is built for the serious angler. It typically includes a higher-speed motor, a telescoping boom, a swivel base, and a dual or triple rod holder as standard features. This is a complete, ready-to-fish system for the dedicated troller.
Captain’s Pak (KP): This is the flagship of the Big Jon line. It includes all the features of the Pro Tournament but often boasts even faster retrieval speeds and the most deluxe components. It is designed for charter captains and tournament professionals who demand the absolute best in terms of speed, power, and reliability day in and day out.

In summary, Big Jon downriggers are a testament to purpose-driven engineering. From the tactile feedback of the manual clutch system to the automated power of the electric models, every component is designed for control, strength, and longevity. By combining aircraft-grade materials with meticulously designed mechanical and electrical systems, Big Jon provides anglers with the precision instruments they need to consistently place their offerings in the strike zone, deep beneath the surface.